Stray light reduction of silicon particle reinforced aluminum for optical systems

Silicon particle reinforced aluminum containing 42 wt.% silicon (Al-42Si) offers higher specific stiffness, higher resistance to thermal gradients, and an athermal behavior combined with electroless nickel, in comparison to state-of-the-art aluminum alloys (e.g. Al6061). Nevertheless, typical surface modifications (e.g. black anodization) lead to a nonsufficient optical stray light suppression due to the high amount of silicon particles on the surface. Therefore, a coating technique is required that fulfils the optical and the mechanical (e.g. adhesive strength) specifications for stray light reduction on Al-42Si. Different components like housings and barrels made of Al-42Si were coated with amorphous NiP and with Fractal Black™ by Acktar Ltd. The optical performance is analyzed by angle-resolved light scattering (ARS) at two different wavelengths (532 nm and 1064 nm). Fractal Black™ offers a total scattering level of lower than 2 % at 532 nm and 1064 nm. Fractal Black™ has been proven as a suitable coating for components made of Al-42Si.