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Design, analysis, and performance of an epoxy-bonded bendable mirror

The toroidal, silicon mirror on microdiffraction beamline 7.3.3 at the Advanced Light Source provides a 1:1 focus of the bend magnet source. The mirror is bent by two lead springs that are bolted to it through a pari of adhesive bonded end blocks. Because of the high loads that these adhesive joints must carry, three specific features of the bonds were tested: bondline geometry of the mating end blocks, surface preparation of the adherends, and strength of the adhesive. Bond strengths were evaluated by loading small test mirrors to failure using two epoxies under two different conditions of surface preparation - acid etching and simple UHV cleaning. In addition, the mirror's temperature distribution and figure errors were calculated with an Ansys Finite Element Model. The model's predictions were correlated to long trace profilometry as well as x-ray focus measurements.