Silvering is the chemical process of coating a non-conductive substrate such as glass with a reflective substance, to produce a mirror. While the metal is often silver, the term is used for the application of any reflective metal.
Silvering is the chemical process of coating a non-conductive substrate such as glass with a reflective substance, to produce a mirror. While the metal is often silver, the term is used for the application of any reflective metal.
Most common household mirrors are "back-silvered" or "second-surface", meaning that the light reaches the reflective layer after passing through the glass. A protective layer of paint is usually applied to protect the back side of the reflective surface . [1] This arrangement protects the fragile reflective layer from corrosion, scratches, and other damage. [2] However, the glass layer may absorb some of the light and cause distortions and optical aberrations due to refraction at the front surface, and multiple additional reflections on it, giving rise to "ghost images" (although some optical mirrors such as Mangins, take advantage of it).
Therefore, precision optical mirrors normally are "front-silvered" or "first-surface", meaning that the reflective layer is on the surface towards the incoming light. The substrate normally provides only physical support, and need not be transparent. A hard, protective, transparent overcoat may be applied to prevent oxidation of the reflective layer and scratching of the metal. Front-coated mirrors achieve reflectivities of 90–95% when new.
Ptolemaic Egypt had manufactured small glass mirrors backed by lead, tin, or antimony. [4] In the early 10th century, the Persian scientist al-Razi described ways of silvering and gilding in a book on alchemy,[ citation needed ] but this was not done for the purpose of making mirrors.
Tin-coated mirrors were first made in Europe in the 15th century. The thin tinfoil used to silver mirrors was known as "tain". [5] When glass mirrors first gained widespread usage in Europe during the 16th century, most were silvered with an amalgam of tin and mercury, [6]
In 1835 German chemist Justus von Liebig developed a process for depositing silver on the rear surface of a piece of glass; this technique gained wide acceptance after Liebig improved it in 1856. [7] [8] The process was further refined and made easier by the chemist Tony Petitjean (1856). [9] This reaction is a variation of the Tollens' reagent for aldehydes. A diamminesilver(I) solution is mixed with a sugar and sprayed onto the glass surface. The sugar is oxidized by silver(I), which is itself reduced to silver(0), i.e. elemental silver, and deposited onto the glass.
In 1856-1857 Karl August von Steinheil and Léon Foucault introduced the process of depositing an ultra-thin layer of silver on the front surface of a piece of glass, making the first optical-quality first surface glass mirrors, replacing the use of speculum metal mirrors in reflecting telescopes. [10] [ dead link ] These techniques soon became standard for technical equipment.
An aluminum vacuum-deposition process invented in 1930 by Caltech physicist and astronomer John Strong, led to most reflecting telescopes shifting to aluminum. [11] Nevertheless, some modern telescopes use silver, such as the Kepler Space Telescope. The Kepler mirror's silver was deposited using ion assisted evaporation. [12] [13]
Silvering aims to produce a non-crystalline coating of amorphous metal (metallic glass), with no visible artifacts from grain boundaries. The most common methods in current use are electroplating, chemical "wet process" deposition, and vacuum deposition.
Electroplating of a substrate of glass or other non-conductive material requires the deposition of a thin layer of conductive but transparent material, such as carbon. This layer tends to reduce the adhesion between the metal and the substrate. [2] (pp 3 & 107) Chemical deposition can result in better adhesion, directly or by pre-treatment of the surface.
Vacuum deposition can produce very uniform coating with very precisely controlled thickness. [2]
The reflective layer on a second surface mirror such as a household mirror is often actual silver. A modern "wet" process for silver coating treats the glass with tin(II) chloride to improve the bonding between silver and glass. An activator is applied after the silver has been deposited to harden the tin and silver coatings. A layer of copper may be added for long-term durability. [14]
Silver would be ideal for telescope mirrors and other demanding optical applications, since it has the best initial front-surface reflectivity in the visible spectrum. However, it quickly oxidizes and absorbs atmospheric sulfur to create a dark, low-reflectivity tarnish.
The "silvering" on precision optical instruments such as telescopes is usually aluminum. Although aluminum also oxidizes quickly, the thin aluminum oxide (sapphire) layer is transparent, and so the high-reflectivity underlying aluminum stays visible.
In modern aluminum silvering, a sheet of glass is placed in a vacuum chamber with electrically heated nichrome coils that can evaporate aluminum. In a vacuum, the hot aluminum atoms travel in straight lines. When they hit the surface of the mirror, they cool and stick.
Some mirror makers evaporate a layer of quartz or beryllia on the mirror; others expose it to pure oxygen or air in an oven so that it will form a tough, clear layer of aluminum oxide.
The first tin-coated glass mirrors were produced by applying a tin-mercury amalgam to the glass and heating the piece to evaporate the mercury.
The "silvering" on infrared instruments is usually gold. It has the best reflectivity in the infrared spectrum, and has high resistance to oxidation and corrosion. Conversely, a thin gold coating is used to create optical filters which block infrared (by mirroring it back towards the source) while passing visible light.
A mirror, also known as a looking glass, is an object that reflects an image. Light that bounces off a mirror will show an image of whatever is in front of it, when focused through the lens of the eye or a camera. Mirrors reverse the direction of the image in an equal yet opposite angle from which the light shines upon it. This allows the viewer to see themselves or objects behind them, or even objects that are at an angle from them but out of their field of view, such as around a corner. Natural mirrors have existed since prehistoric times, such as the surface of water, but people have been manufacturing mirrors out of a variety of materials for thousands of years, like stone, metals, and glass. In modern mirrors, metals like silver or aluminium are often used due to their high reflectivity, applied as a thin coating on glass because of its naturally smooth and very hard surface.
In physics, sputtering is a phenomenon in which microscopic particles of a solid material are ejected from its surface, after the material is itself bombarded by energetic particles of a plasma or gas. It occurs naturally in outer space, and can be an unwelcome source of wear in precision components. However, the fact that it can be made to act on extremely fine layers of material is utilised in science and industry—there, it is used to perform precise etching, carry out analytical techniques, and deposit thin film layers in the manufacture of optical coatings, semiconductor devices and nanotechnology products. It is a physical vapor deposition technique.
Electroplating, also known as electrochemical deposition or electrodeposition, is a process for producing a metal coating on a solid substrate through the reduction of cations of that metal by means of a direct electric current. The part to be coated acts as the cathode of an electrolytic cell; the electrolyte is a solution of a salt whose cation is the metal to be coated, and the anode is usually either a block of that metal, or of some inert conductive material. The current is provided by an external power supply.
Amateur telescope making is the activity of building telescopes as a hobby, as opposed to being a paid professional. Amateur telescope makers build their instruments for personal enjoyment of a technical challenge, as a way to obtain an inexpensive or personally customized telescope, or as a research tool in the field of astronomy. Amateur telescope makers are usually a sub-group in the field of amateur astronomy.
Indium tin oxide (ITO) is a ternary composition of indium, tin and oxygen in varying proportions. Depending on the oxygen content, it can be described as either a ceramic or an alloy. Indium tin oxide is typically encountered as an oxygen-saturated composition with a formulation of 74% In, 8% Sn, and 18% O by weight. Oxygen-saturated compositions are so typical that unsaturated compositions are termed oxygen-deficient ITO. It is transparent and colorless in thin layers, while in bulk form it is yellowish to gray. In the infrared region of the spectrum it acts as a metal-like mirror.
An optical coating is one or more thin layers of material deposited on an optical component such as a lens, prism or mirror, which alters the way in which the optic reflects and transmits light. These coatings have become a key technology in the field of optics. One type of optical coating is an anti-reflective coating, which reduces unwanted reflections from surfaces, and is commonly used on spectacle and camera lenses. Another type is the high-reflector coating, which can be used to produce mirrors that reflect greater than 99.99% of the light that falls on them. More complex optical coatings exhibit high reflection over some range of wavelengths, and anti-reflection over another range, allowing the production of dichroic thin-film filters.
Speculum metal is a mixture of around two-thirds copper and one-third tin, making a white brittle alloy that can be polished to make a highly reflective surface. It was used historically to make different kinds of mirrors from personal grooming aids to optical devices until it was replaced by more modern materials such as metal-coated glass mirrors.
A thin film is a layer of material ranging from fractions of a nanometer (monolayer) to several micrometers in thickness. The controlled synthesis of materials as thin films is a fundamental step in many applications. A familiar example is the household mirror, which typically has a thin metal coating on the back of a sheet of glass to form a reflective interface. The process of silvering was once commonly used to produce mirrors, while more recently the metal layer is deposited using techniques such as sputtering. Advances in thin film deposition techniques during the 20th century have enabled a wide range of technological breakthroughs in areas such as magnetic recording media, electronic semiconductor devices, integrated passive devices, light-emitting diodes, optical coatings, hard coatings on cutting tools, and for both energy generation and storage. It is also being applied to pharmaceuticals, via thin-film drug delivery. A stack of thin films is called a multilayer.
Plating is a finishing process in which a metal is deposited on a surface. Plating has been done for hundreds of years; it is also critical for modern technology. Plating is used to decorate objects, for corrosion inhibition, to improve solderability, to harden, to improve wearability, to reduce friction, to improve paint adhesion, to alter conductivity, to improve IR reflectivity, for radiation shielding, and for other purposes. Jewelry typically uses plating to give a silver or gold finish.
Metallizing is the general name for the technique of coating metal on the surface of objects. Metallic coatings may be decorative, protective or functional.
Low emissivity refers to a surface condition that emits low levels of radiant thermal (heat) energy. All materials absorb, reflect, and emit radiant energy according to Planck's law but here, the primary concern is a special wavelength interval of radiant energy, namely thermal radiation of materials. In common use, especially building applications, the temperature range of approximately -40 to +80 degrees Celsius is the focus, but in aerospace and industrial process engineering, much broader ranges are of practical concern.
Electron-beam physical vapor deposition, or EBPVD, is a form of physical vapor deposition in which a target anode is bombarded with an electron beam given off by a charged tungsten filament under high vacuum. The electron beam causes atoms from the target to transform into the gaseous phase. These atoms then precipitate into solid form, coating everything in the vacuum chamber with a thin layer of the anode material.
Vacuum deposition is a group of processes used to deposit layers of material atom-by-atom or molecule-by-molecule on a solid surface. These processes operate at pressures well below atmospheric pressure. The deposited layers can range from a thickness of one atom up to millimeters, forming freestanding structures. Multiple layers of different materials can be used, for example to form optical coatings. The process can be qualified based on the vapor source; physical vapor deposition uses a liquid or solid source and chemical vapor deposition uses a chemical vapor.
Physical vapor deposition (PVD), sometimes called physical vapor transport (PVT), describes a variety of vacuum deposition methods which can be used to produce thin films and coatings on substrates including metals, ceramics, glass, and polymers. PVD is characterized by a process in which the material transitions from a condensed phase to a vapor phase and then back to a thin film condensed phase. The most common PVD processes are sputtering and evaporation. PVD is used in the manufacturing of items which require thin films for optical, mechanical, electrical, acoustic or chemical functions. Examples include semiconductor devices such as thin-film solar cells, microelectromechanical devices such as thin film bulk acoustic resonator, aluminized PET film for food packaging and balloons, and titanium nitride coated cutting tools for metalworking. Besides PVD tools for fabrication, special smaller tools used mainly for scientific purposes have been developed.
Evaporation is a common method of thin-film deposition. The source material is evaporated in a vacuum. The vacuum allows vapor particles to travel directly to the target object (substrate), where they condense back to a solid state. Evaporation is used in microfabrication, and to make macro-scale products such as metallized plastic film.
An electrochromic device (ECD) controls optical properties such as optical transmission, absorption, reflectance and/or emittance in a continual but reversible manner on application of voltage (electrochromism). This property enables an ECD to be used for applications like smart glass, electrochromic mirrors, and electrochromic display devices.
Sputter deposition is a physical vapor deposition (PVD) method of thin film deposition by the phenomenon of sputtering. This involves ejecting material from a "target" that is a source onto a "substrate" such as a silicon wafer. Resputtering is re-emission of the deposited material during the deposition process by ion or atom bombardment. Sputtered atoms ejected from the target have a wide energy distribution, typically up to tens of eV. The sputtered ions can ballistically fly from the target in straight lines and impact energetically on the substrates or vacuum chamber. Alternatively, at higher gas pressures, the ions collide with the gas atoms that act as a moderator and move diffusively, reaching the substrates or vacuum chamber wall and condensing after undergoing a random walk. The entire range from high-energy ballistic impact to low-energy thermalized motion is accessible by changing the background gas pressure. The sputtering gas is often an inert gas such as argon. For efficient momentum transfer, the atomic weight of the sputtering gas should be close to the atomic weight of the target, so for sputtering light elements neon is preferable, while for heavy elements krypton or xenon are used. Reactive gases can also be used to sputter compounds. The compound can be formed on the target surface, in-flight or on the substrate depending on the process parameters. The availability of many parameters that control sputter deposition make it a complex process, but also allow experts a large degree of control over the growth and microstructure of the film.
Substrate is a term used in materials science and engineering to describe the base material on which processing is conducted. Surfaces have different uses, including producing new film or layers of material and being a base to which another substance is bonded.
Combustion chemical vapor deposition (CCVD) is a chemical process by which thin-film coatings are deposited onto substrates in the open atmosphere.
Chemical Bath Deposition, also called Chemical Solution Deposition and CBD, is a method of thin-film deposition, using an aqueous precursor solution. Chemical Bath Deposition typically forms films using heterogeneous nucleation, to form homogeneous thin films of metal chalcogenides and many less common ionic compounds. Chemical Bath Deposition produces films reliably, using a simple process with little infrastructure, at low temperature (<100˚C), and at low cost. Furthermore, Chemical Bath Deposition can be employed for large-area batch processing or continuous deposition. Films produced by CBD are often used in semiconductors, photovoltaic cells, and supercapacitors, and there is increasing interest in using Chemical Bath Deposition to create nanomaterials.
Episode 305 filmed at Verrerie-Walker.
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