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Optimal Magnetorheological Fluid for Finishing of Chemical-Vapor

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Optimal Magnetorheological Fluid for Finishing of Chemical-Vapor Optimal Magnetorheological Fluid for Finishing of Chemical-Vapor-Deposited Zinc Sulfide by Sivan Salzman Submitted in Partial Fulfillment of the Requirements for the Degree of Doctor of Philosophy Supervised by Professor John C. Lambropoulos and Professor Stephen D. Jacobs (deceased) Materials Science Program Arts, Sciences and Engineering Edmund A. Hajim School of Engineering and Applied Sciences University of Rochester 2016 ii To my beloved children, Avishag and Evyatar iii Biographical Sketch The author was born in Karmiel, Israel, in 1982. She enrolled at the ORT Braude College of Engineering in 2004 as a student in the Mechanical Engineering Department. In 2006 she spent one semester at the University of Rochester as part of the Study Abroad Program. She returned to the University of Rochester a year later for a six month internship under the direction of Professor Stephen D. Jacobs at the Laboratory for Laser Energetics (LLE). During this time she investigated the importance of substrate surface finish (coarse to fine ground) on the drag force generated during the magnetorheological finishing process. The author graduated cum laude with a Bachelor of Science degree from the ORT Braude College of Engineering in 2008. That same year she began her graduate studies at the University of Rochester in the Materials Science Program under the direction of Professor Stephen D. Jacobs. The author received a Master of Science degree in 2009 and began doctoral studies in the Materials Science Program a year later. Her PhD research, which was carried out at the LLE at the University of Rochester, was supervised by Professor Stephen D. Jacobs, Professor John C. Lambropoulos, and Kenneth L. Marshall. Contributions of her doctoral research include the development of a novel, low pH magnetorheological finishing fluid to reduce surface artifacts and improve the surface roughness of infrared optical components made of chemical-vapor-deposited zinc sulfide. The author was awarded the Frank J. Horton Graduate Research Fellowship to support her graduate work. iv The following publications resulted from work conducted during graduate study at the University of Rochester: Refereed journal articles 1. S. Salzman, H. J. Romanofsky, K. L. Marshall, S. D. Jacobs, and J. C. Lambropoulos, “Acidic magnetorheological finishing of infrared materials,” Submitted for publication in Applied Optics. 2. S. Salzman, H. J. Romanofsky, L. J. Giannechini, S. D. Jacobs, and J. C. Lambropoulos, “Magnetorheological finishing of chemical-vapor-deposited zinc sulfide via chemically and mechanically modified fluids,” Applied Optics 55, 1481-1489 (2016). 3. S. Salzman, H. J. Romanofsky, S. D. Jacobs, and J. C. Lambropoulos, “Surface– texture evolution of different chemical-vapor-deposited zinc sulfide flats polished with various magnetorheological fluids,” Precision Engineering 43, 257-261 (2016). 4. S. N. Shafrir, H. J. Romanofsky, M. Skarlinski, M. Wang, C. Miao, S. Salzman, T. Chartier, J. Mici, J. C. Lambropoulos, R. Shen, H. Yang, and S. D. Jacobs, “Zirconia-coated carbonyl-iron-particle-based magnetorheological fluid for polishing optical glasses and ceramics,” Applied Optics 48, 6797-6810 (2009). v Published proceedings 5. S. Salzman, L. J. Giannechini, H. J. Romanofsky, N. Golini, B. Taylor, S. D. Jacobs, and J. C. Lambropoulos, “Advanced zirconia-coated carbonyl-iron particles for acidic magnetorheological finishing of chemical-vapor-deposited ZnS and other IR materials,” in Optifab 2015, J. L. Bentley and S. Stoebenau (SPIE, 2015), Vol. 9633, Paper 963307. 6. S. Salzman, H. J. Romanofsky, Y. I. Clara, L. J. Giannechini, G. West, J. C. Lambropoulos, and S. D. Jacobs, “Magnetorheological finishing with chemically modified fluids for studying material removal of single crystal ZnS,” in Optifab 2013, J. L. Bentley and M. Pfaff (SPIE, 2013), Vol. 8884, Paper 888407. 7. S. N. Shafrir, H. J. Romanofsky, M. Skarlinski, M. Wang, C. Miao, S. Salzman, T. Chartier, J. Mici, J. C. Lambropoulos, R. Shen, H. Yang, and S. D. Jacobs, “Zirconia coated carbonyl iron particle-based magnetorheological fluid for polishing,” in Optical Manufacturing and Testing VIII, J. H. Burge, O. W. Fähnle, and R. Williamson (SPIE, 2009), Vol. 7426, Paper 74260B. Non-refereed articles 8. Sivan Salzman, Henry J. Romanofsky, Kenneth L. Marshall, Stephen D. Jacobs, and John C. Lambropoulos, “Acidic magnetorheological finishing of infrared materials,” LLE Review 146, (2016). 9. Sivan Salzman, Henry J. Romanofsky, Lucca J. Giannechini, Stephen D. Jacobs, and John C. Lambropoulos, “Magnetorheological finishing of chemical-vapor- vi deposited zinc sulfide via chemically and mechanically modified fluids,” LLE Review 144, 185–194 (2015). 10. Sivan Salzman, Henry J. Romanofsky, Stephen D. Jacobs, and John C. Lambropoulos, “Surface–texture evolution of different chemical-vapor-deposited zinc sulfide flats polished with various magnetorheological fluids,” LLE Review 142, 110–115 (2015). 11. Shai N. Shafrir, Henry J. Romanofsky, Michael Skarlinski, Mimi Wang, Chunlin Miao, Sivan Salzman, Taylor Chartier, Joni Mici, John C. Lambropoulos, Rui Shen, Hong Yang, and Stephen D. Jacobs, “Zirconia-coated carbonyl-iron- particle-based magnetorheological fluid for polishing optical glasses and ceramics,” LLE Review 120, 190–205 (2009). Presentations 12. S. Salzman and K. Mehrotra, “Structure of sol-gel derived nanozirconia-coated carbonyl iron particles used in magnetorheological finishing,” Nanomaterials Symposium 2011: Frontiers in Materials Science for the 21st Century, University of Rochester, May 23, 2011. vii Acknowledgments I express my sincere gratitude to my principal advisor, the late Professor Stephen D. Jacobs who encouraged me to pursue a PhD degree in the first place. His love and enthusiasm for science were inspiring, and I am thankful for all the years I spent with him, learning how to become a scientist. I also appreciate the patience, encouragement, and absolute support he provided me throughout my graduate studies. My sincere gratitude goes to my second principal advisor, Professor John C. Lambropoulos, whose unconditional guidance and support brought me to the finish line. His expertise and words of advice were invaluable to me. I owe many thanks to Kenneth Marshall, who mentored and supervised me at LLE. His experience, valuable advice, patience, and constant encouragement made it possible for me to keep going and complete my degree. My thanks go to my thesis committee members, Professor Jonathan D. Ellis, Professor Matthew Z. Yates and Professor Jannick Rolland for contributing their time and expertise. I thank two dear people who were like family to me in the past few years: Henry Romanofsky for his generous assistance at the lab with experiments, metrology, and routine assignments, but mostly, for a wonderful friendship and companionship in the lab and outside; and master optician Alex Maltsev for going the extra mile and making the impossible to help me pursue my work. I am extremely grateful to Lucca J. Giannechini whose commitment and hard work to improve the corrosion resistance of the CI particles made it possible for me to viii accomplish my doctoral thesis goals. I also thank high school student Nicholas Golini, for his dedicated work during two summers at LLE in our Optical Materials Technology group. I thank Brittany Hoffman for her help around the lab, and for her friendship—especially at difficult times. It was a privilege to have a former fellow PhD student Dr. Karan Mehrotra as a colleague in the Materials Science Program who was always available when his microscopy expertise and opinion were needed. I am deeply appreciative of Rochester Institute of Technology co-operative education student Yoem Clara, as well as University of Rochester student Garrett West. Their excellent work in support of this research made a great difference. I was glad to have former and present fellow PhD students Dr. Chunlin Miao, Dr. Gerald Cox, Dr. Heather Liddell, Katelynn Sharma, and Debbie Saulnier as colleagues in the Optical Materials Technology group, with whom I shared an office and many pleasant conversations. I must express my gratitude to QED Technologies—especially Eric Oswald, Arpad Sekeres, Dr. Sergei Gorodkin, and Paul Dumas, for letting me use their facility and equipment, for sharing their expertise, and for their outreaching hospitality; and to Peter Droste from SurfaceNet GmbH who was the only supplier that agreed to custom-make the single crystal orientations of ZnS that were a fundamental part of my research. My deep appreciation is owed to Professor Stephen J. Burns, whose enthusiasm and endless knowledge of Materials Science were inspirational through our directed reading. I always left our discussions filled with motivation. I am ix grateful to Chris Pratt of the Mechanical Engineering Department, for her uncompromising help, and for hours of x-ray diffraction measurements and analysis; and to Brian McIntyre for his dedication and tremendous support on the SEM and TEM. I also thank Professor Hong Yang for providing his valuable time and advice for this project. I received substantial help from many people at LLE and some deserve particular mention. I thank Dr. Shai Shafrir for introducing me to Professor Stephen D. Jacobs as an undergraduate student, and for being an extraordinary mentor at the beginning of my graduate studies path. Many thanks go to the Publications and Design Department—especially to Jennifer Taylor, Lisa Stappenbacher, Peggy Tyler, Jennifer Hamson, Heidi
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