Freeform optics provide excellent performance for a wide variety of applications. However, obtaining an accurate freeform surface measurement is highly challenging due to its large aspheric/freeform departure. It has been proven that SCOTS (Software Configurable Optical Test System), an advanced deflectometry system developed at the University of Arizona, can measure the departure of a freeform surface from the desired shape with nanometer accuracy. Here, a new data processing technique was used to measure a freeform surface without any prior knowledge of the shape of the surface. Knowing only the geometry of one point on the test surface, this method can take a blind measurement of a freeform surface and arrive at the true surface through iterative construction.

Daniel K. Inouye Solar Telescope (formerly known as Advanced Technology Solar Telescope) will be the largest optical solar telescope ever built to provide greatly improved image, spatial and spectral resolution and to collect sufficient light flux of Sun. To meet the requirements of the telescope the design adopted a 4m aperture off-axis parabolic primary mirror with challenging specifications of the surface quality including the surface figure, irregularity and BRDF. The mirror has been completed at the College of Optical Sciences in the University of Arizona and it meets every aspect of requirement with margin. In fact this mirror may be the smoothest large mirror ever made. This paper presents the detail fabrication process and metrology applied to the mirror from the grinding to finish, that include extremely stable hydraulic support, IR and Visible deflectometry, Interferometry and Computer Controlled fabrication process developed at the University of Arizona.

New optical designs strive to achieve extreme performance, and continually increase the complexity of prescribed optical shapes, which often require wide dynamic range and high resolution. SCOTS, or the Software Configurable Optical Test System, can measure a wide range of optical surfaces with high sensitivity using surface slope. This dissertation introduces a high resolution version of SCOTS called SPOTS, or the Slope measuring Portable Optical Test System. SPOTS improves the metrology of surface features on the order of sub-millimeter to decimeter spatial scales and nanometer to micrometer level height scales. Currently there is no optical surface metrology instrument with the same utility. SCOTS uses a computer controlled display (such as an LCD monitor) and camera to measure surface slopes over the entire surface of a mirror. SPOTS differs in that an additional lens is placed near the surface under test. A small prototype system is discussed in general, providing the support for the design of future SPOTS devices. Then the SCOTS instrument transfer function is addressed, which defines the way the system filters surface heights. Lastly, the calibration and performance of larger SPOTS device is analyzed with example measurements of the 8.4-m diameter aspheric Large Synoptic Survey Telescope's (LSST) primary mirror. In general optical systems have a transfer function, which filters data. In the case of optical imaging systems the instrument transfer function (ITF) follows the modulation transfer function (MTF), which causes a reduction of contrast as a function of increasing spatial frequency due to diffraction. In SCOTS, ITF is shown to decrease the measured height of surface features as their spatial frequency increases, and thus the SCOTS and SPOTS ITF is proportional to their camera system's MTF. Theory and simulations are supported by a SCOTS measurement of a test piece with a set of lithographically written sinusoidal surface topographies. In addition, an example of a simple inverse filtering technique is provided. The success of a small SPOTS proof of concept instrument paved the way for a new larger prototype system, which is intended to measure subaperture regions on large optical mirrors. On large optics, the prototype SPOTS is light weight and it rests on the surface being tested. One advantage of this SPOTS is stability over time in maintaining its calibration. Thus the optician can simply place SPOTS on the mirror, perform a simple alignment, collect measurement data, then pick the system up and repeat at a new location. The entire process takes approximately 5 to 10 minutes, of which 3 minutes is spent collecting data. SPOTS' simplicity of design, light weight, robustness, wide dynamic range, and high sensitivity make it a useful tool for optical shop use during the fabrication and testing process of large and small optics.

Aspherical optics are increasingly used these days. The application of aspherical surfaces on large, astronomical telescope mirrors brings challenge to the fabrication. Since the surface radius of curvature varies across the surface, the grinding/polishing tool needs to change its shape when working on different parts of the surface, making surface error more easily embedded into the surface. Therefore, a tighter test-fab loop is needed to guide the fabrication process. To maximize the accuracy during the grinding of the surface and to minimize the working time in the polishing stage, a better metrology device that can measure rough surface is needed to guide the grinding process. Scanning long-wave optical test system (SLOTS) is designed to meet this demand by providing accurate, fast, large dynamic range, and high spatial resolution measurements on rough optical surfaces (surface rms roughness<1.7 µm).SLOTS is a slope measuring deflectometry system that works like a reversed wire test. It measures the reflection of the infrared light off the test surface, and calculates the local slope of the test surface. The surface sag/height is obtained through integration. During the test, a heated metal ribbon radiates long-wave infrared light that is reflected by the test surface. A thermal imaging camera records the reflected light. The ribbon is scanned in two orthogonal directions. From the variation of the irradiance recorded by the camera, slope maps of the test surface can be retrieved in the two orthogonal directions. SLOTS is a combination of tradition slope measurement and modern technology, processing advantages from both parts. It measures surface slope, so there is no need for null optics. It uses an uncooled thermal imaging camera that is made with high resolution and high sensitivity. The linear stage used to scan the hot ribbon has long travel, small resolution, and high accuracy. Both the camera and stage enable SLOTS a large dynamic range and high sensitivity. SLOTS has successfully guided the grinding process of the primary mirror of Daniel K. Inouye Solar Telescope. This mirror is a 4-meter diameter off-axis parabola (OAP). Its largest aspherical departure is 8 mm. SLOTS is able to measure it without any null optics. Under the guidance of SLOTS, the surface shape was controlled to be 1 µm rms within designed shape (with astigmatism removed) at 0.7 µm rms surface roughness (12 µm loose abrasive grits).

In the fringe-illumination deflectometry based on reverse-Hartmann-test configuration, ray tracing of the modeled testing system is performed to reconstruct the test surface error. Careful calibration of system geometry is required to achieve high testing accuracy. To realize the high-precision surface testing with reverse Hartmann test, a computer-aided geometrical error calibration method is proposed. The aberrations corresponding to various geometrical errors are studied. With the aberration weights for various geometrical errors, the computer-aided optimization of system geometry with iterative ray tracing is carried out to calibration the geometrical error, and the accuracy in the order of sub-nanometer is achieved.

Jusqu’à récemment, la plupart des applications des arcs électriques mettaient en oeuvre les propriétés du coeur de la colonne, un effort particulier a donc été effectué pour développer des méthodes de caractérisation de ces zones dont la température moyenne est de l’ordre de 10000 K. Avec le développement de la plasma-chimie, le diagnostic des zones périphériques d’arcs et des décharges hors équilibre est devenu un enjeu primordial. Les méthodes de mesure classiques sont mal adaptées pour cette tâche ; le but du travail présenté dans cette thèse se résume donc au développement et à la validation de techniques de diagnostic adaptées à ces zones, dont la température cinétique n’excède pas 8000 K. Deux méthodes innovantes basées sur l’indice de réfraction, l’ombroscopie quantitative et la déflectométrie moirée, ont été étudiées en détails. Les résultats théoriques ainsi que le traitement des données obtenues ont été validés sur un jet de plasma laminaire d’argon, un modèle parfait de zone périphérique. Pour sonder les décharges hors équilibre, l’utilisation du spectre UV de OH a été aussi envisagée. À cette occasion, un programme de simulation de spectre moléculaire a été développé. L’étude des spectres synthétiques obtenus a permis de mettre au point des méthodes de mesure simples de la température rotationnelle et vibrationnelle pour une large gamme de résolution. Une des méthodes développées a été mise en œuvre sur une décharge à faible intensité de courant. On montre que les résultats obtenus par spectroscopie moléculaire sur le radical OH sont très proches de ceux obtenus à l’aide d’une simulation. / Until recently, most of electrical arcs applications were dealing with the properties of the centre of the plasma column, a large number of works was then done to develop diagnostic techniques dedicated to those area where the mean temperature is about 10000 K. With the emergence of plasma chemistery, the diagnostic of arc’s peripheral areas and un-equilibrium discharges become a goal of prime importance. Classical diagnostic techniques are not adapted to those objects where the maximum temperature is around 8000 K; the principal aim of this work was to develop and check diagnostic techniques. Two inovating techniques based on refractive index, the quantitative shadowgraphy and the moiré deflectometry were studied extensively and checked on a laminar plasma jet, a perfect model of arc’s peripheral area. To probe unequilibrium discharge, the use of UV OH spectrum was considered. At this occasion, a spectrum simulation software was written. The study of synthetic spectra lead to the creation of simple measurement methods of rotationnal and vibrationnal OH temperature for a large range of resolution. Those methods was checked on a low power electric discharge. It can be shown that result from molecular spectroscopy are close to those obtained by simulation.

In this thesis we conclude that convolutional neural networks, together with phase-measuring deflectometry techniques, can be used to create models which can detect and classify defects on painted surfaces very well, even compared to experienced humans. Further, we show which preprocessing measures enhances the performance of the models. We see that standardisation does increase the classification accuracy of the models. We demonstrate that cleaning the data through relabelling and removing faulty images improves classification accuracy and especially the models' ability to distinguish between different types of defects. We show that oversampling might be a feasible method to improve accuracy through increasing and balancing the data set by augmenting existing observations. Lastly, we find that combining many images with different patterns heavily increases the classification accuracy of the models. Our proposed approach is demonstrated to work well in a real-time factory environment. An automated quality control of the painted surfaces of Volvo Truck cabins could give great benefits in cost and quality. The automated quality control could provide data for a root-cause analysis and a quick and efficient alarm system. This could significantly streamline production and at the same time reduce costs and errors in production. Corrections and optimisation of the processes could be made in earlier stages in time and with higher precision than today. / I den här rapporten visar vi att modeller av typen convolutional neural networks, tillsammans med phase-measuring deflektometri, kan hitta och klassificera defekter på målade ytor med hög precision, även jämfört med erfarna operatörer. Vidare visar vi vilka databehandlingsåtgärder som ökar modellernas prestanda. Vi ser att standardisering ökar modellernas klassificeringsförmåga. Vi visar att städning av data genom ommärkning och borttagning av felaktiga bilder förbättrar klassificeringsförmågan och särskilt modellernas förmåga att särskilja mellan olika typer av defekter. Vi visar att översampling kan vara en metod för att förbättra precisionen genom att öka och balansera datamängden genom att förändra och duplicera befintliga observationer. Slutligen finner vi att kombinera flera bilder med olika mönster ökar modellernas klassificeringsförmåga väsentligt. Vårt föreslagna tillvägagångssätt har visat sig fungera bra i realtid inom en produktionsmiljö. En automatiserad kvalitetskontroll av de målade ytorna på Volvos lastbilshytter kan ge stora fördelar med avseende på kostnad och kvalitet. Den automatiska kvalitetskontrollen kan ge data för en rotorsaksanalys och ett snabbt och effektivt alarmsystem. Detta kan väsentligt effektivisera produktionen och samtidigt minska kostnader och fel i produktionen. Korrigeringar och optimering av processerna kan göras i tidigare skeden och med högre precision än idag.

Le travail présenté dans cette thèse porte sur l'inspection de surfaces métalliques industrielles. Nous proposons de généraliser des méthodes de l'imagerie hyperspectrale à des données multimodales comme des images optiques multi-canales, et des images thermographiques multi-temporelles. Dans la première application, les cubes de données sont construits à partir d'images multi-composantes pour détecter des défauts de surface. Les meilleures performances sont obtenues avec les éclairages multi-longueurs d'ondes dans le visible et le proche IR, et la détection du défaut en utilisant l'angle spectral, avec le spectre moyen comme référence. La deuxième application concerne l'utilisation de l'imagerie thermique pour l'inspection de pièces métalliques nucléaires afin de détecter des défauts de surface et sub-surface. Une approche 1D est proposée, basée sur l'utilisation du kurtosis pour sélectionner la composante principale parmi les premières obtenues après réduction des données avec l’ACP. La méthode proposée donne de bonnes performances avec des données non-bruitées et homogènes, cependant la SVD avec les algorithmes de détection d'anomalies est très robuste aux perturbations. Finalement, une approche, basée sur les techniques d'analyse de franges et la lumière structurée est présentée, dans le but d'inspecter des surfaces métalliques à forme libre. Après avoir déterminé les paramètres décrivant les modèles de franges sinusoïdaux, l'approche proposée consiste à projeter une liste de motifs déphasés et à calculer l'image de phase des motifs enregistrés. La localisation des défauts est basée sur la détection et l'analyse des franges dans les images de phase. / The work presented in this thesis deals with the quality control and inspection of industrial metallic surfaces. The purpose is the generalization and application of hyperspectral imagery methods for multimodal data such as multi-channel optical images and multi-temporal thermographic images. In the first application, data cubes are built from multi-component images to detect surface defects within flat metallic parts. The best performances are obtained with multi-wavelength illuminations in the visible and near infrared ranges, and detection using spectral angle mapper with mean spectrum as a reference. The second application turns on the use of thermography imaging for the inspection of nuclear metal components to detect surface and subsurface defects. A 1D approach is proposed based on using the kurtosis to select 1 principal component (PC) from the first PCs obtained after reducing the original data cube with the principal component analysis (PCA) algorithm. The proposed PCA-1PC method gives good performances with non-noisy and homogeneous data, and SVD with anomaly detection algorithms gives the most consistent results and is quite robust to perturbations such as inhomogeneous background. Finally, an approach based on fringe analysis and structured light techniques in case of deflectometric recordings is presented for the inspection of free-form metal surfaces. After determining the parameters describing the sinusoidal stripe patterns, the proposed approach consists in projecting a list of phase-shifted patterns and calculating the corresponding phase-images. Defect location is based on detecting and analyzing the stripes within the phase-images.

We have harnessed the power of programmable photonics devices for an interferometric measurement technique. Laser interferometers are widely used for flow velocity measurements, since they offer high temporal and spatial resolutions. However, often optical wavefront distortions deteriorate the measurement properties. In principle, adaptive optics enables the correction of these disturbances. One challenge is to generate a suitable reference signal for the closed loop operation of the adaptive optics. An adaptive Mach Zehnder interferometer is presented to measure through a dynamic liquid-gas phase boundary, which can lead to a misalignment of the interfering laser beams. In order to generate the reference signal for the closed loop control, the Fresnel reflex of the phase boundary is used as Laser Guide Star (LGS) for the first time to the best of the authors’ knowledge. The concept is related to the generation of artificial stars in astronomy, where the light transmitted by the atmosphere is evaluated. However, the adaptive interferometric flow velocity measurements at real world experiments require a different concept, since only the reflected light can be evaluated. The used LGS allows to measure the wavefront distortions induced by the dynamic phase boundary. Two biaxial electromagnetically driven steering mirrors are employed to correct the wavefront distortions. This opens up the possibility for accurate flow measurements through a dynamic phase boundary using only one optical access. Our work represents a paradigm shift in interferometric velocity measurement techniques from using static to dynamic optical elements.