Optics Recycle Loop Strategy for NIF Operations above UV Laser-Induced Damage Threshold

Effect of 3D surface topographies on the temperature field of machined potassium dihydrogen phosphate crystals

3D actual frequencies in the machined Potassium dihydrogen phosphate (KH2PO4, KDP) crystal surfaces are extracted and reconstructed through continuous wavelet transform (CWT) and power spectral density (PSD) methods. The temperatures of machined KDP crystals, which are exposed to laser irradiation with a wavelength of 1.064 μm and power of 200 MW/μm2 in 1 ns, are analyzed with wave optics. The ideal surfaces have been selected to analyze the impact of wavelength and amplitude on the internal temperature field of KDP crystals. Along the orthogonal direction of cutting, the closer the dominant 3D wavelength of the surface is to the laser's incident wavelength, the greater the temperature increase. The maximum temperature decreases with the further increase of the wavelength (1.064-20 μm). The effect of the frequency feature on temperature in the cutting direction is similar to that in the orthogonal direction, but with a lesser impact on temperature variation. The temperatures of 3D surfaces and sub-surfaces above 10 μm depth are calculated using the wave optics theory. The maximum temperature field throughout the crystal is in the subsurface layer. With the increase of wavelength, the positions of the maximum temperature extend to the interior of the KDP crystal.

Separation and Analysis of Connected, Micrometer-Sized, High-Frequency Damage on Glass Plates due to Laser-Accelerated Material Fragments in Vacuum

In this paper, we present a new processing method, called MOSES-Impacts, for the detection of micrometer-sized damage on glass plate surfaces. It extends existing methods by a separation of damaged areas, called impacts, to support state-of-the-art recycling systems in optimizing their parameters. These recycling systems are used to repair process-related damages on glass plate surfaces, caused by accelerated material fragments, which arise during a laser-matter interaction in a vacuum. Due to a high number of impacts, the presented MOSES-Impacts algorithm focuses on the separation of connected impacts in two-dimensional images. This separation is crucial for the extraction of relevant features such as centers of gravity and radii of impacts, which are used as recycling parameters. The results show that the MOSES-Impacts algorithm effectively separates impacts, achieves a mean agreement with human users of (82.0 ± 2.0)%, and improves the recycling of glass plate surfaces by identifying around 7% of glass plate surface area as being not in need of repair compared to existing methods.

Evolution mechanism of subsurface damage during laser machining process of fused silica

The machining-induced subsurface damage (SSD) on fused silica optics would incur damage when irradiated by intense lasers, which severely restricts the service life of fused silica optics. The high absorption of fused silica to 10.6 µm makes it possible to utilize pulsed CO2 laser to remove and characterize SSD by layer-by-layer ablation, which improves its laser-induced damage threshold. However, thermal stress during the laser ablation process may have an impact on SSD, leading to extension. Still, the law of SSD morphology evolution mechanism has not been clearly revealed. In this work, a multi-physics simulated model considering light field modulation is established to reveal the evolution law of radial SSD during the laser layer-by-layer ablation process. Based on the simulation of different characteristic structural parameters, two evolution mechanisms of radial SSD are revealed, and the influence of characteristic structural parameters on SSD is also elaborated. By prefabricating the SSD by femtosecond laser, the measurements of SSD during CO2 laser layer-by-layer ablation experiments are consistent with the simulated results, and three stages of SSD depth variation under two evolution processes are further proposed. The findings of this study provide theoretical guidance for effectively characterizing SSD based on laser layer-by-layer ablation strategies on fused silica optics.

The impact of low-mode symmetry on inertial fusion energy output in the burning plasma state

Indirect Drive Inertial Confinement Fusion Experiments on the National Ignition Facility (NIF) have achieved a burning plasma state with neutron yields exceeding 170 kJ, roughly 3 times the prior record and a necessary stage for igniting plasmas. The results are achieved despite multiple sources of degradations that lead to high variability in performance. Results shown here, for the first time, include an empirical correction factor for mode-2 asymmetry in the burning plasma regime in addition to previously determined corrections for radiative mix and mode-1. Analysis shows that including these three corrections alone accounts for the measured fusion performance variability in the two highest performing experimental campaigns on the NIF to within error. Here we quantify the performance sensitivity to mode-2 symmetry in the burning plasma regime and apply the results, in the form of an empirical correction to a 1D performance model. Furthermore, we find the sensitivity to mode-2 determined through a series of integrated 2D radiation hydrodynamic simulations to be consistent with the experimentally determined sensitivity only when including alpha-heating.

Research on the mitigation of redeposition defects on the fused silica surface during wet etching process

The laser-induced damage of ultraviolet fused silica optics is a critical factor that limits the performance enhancement of high-power laser facility. Currently, wet etching technology based on hydrofluoric acid (HF) can effectively eliminate absorbing impurities and subsurface defects, thereby significantly enhancing the damage resistance of fused silica optics. However, with an increase in the operating fluence, the redeposition defects generated during wet etching gradually become the primary bottleneck that restricts its performance improvement. The composition and morphology of redeposition defects were initially identified in this study, followed by an elucidation of their formation mechanism. A mitigation strategy was then proposed, which combines a reduction in the generation of precipitation with an acceleration of the precipitation dissolution process. Additionally, we systematically investigated the influence of various process parameters such as extrinsic impurity, etching depth, and megasonic excitation on the mitigation of deposition defects. Furthermore, a novel multiple-step dynamic etching method was developed. Through comprehensive characterization techniques, it has been confirmed that this new etching process not only effectively mitigate redeposition defects under low fluence conditions but also exhibits significant inhibition effects on high fluence precursors. Consequently, it significantly enhances the laser damage resistance performance of fused silica optics.

Ultrafast Process Characterization of Laser-Induced Damage in Fused Silica Using Pump-Probe Shadow Imaging Techniques

This study delves into the intricate dynamics of laser-induced damage in fused silica using a time-resolved pump-probe (TRPP) shadowgraph. Three typical ultra-fast processes, laser-induced plasma evolution, shockwave propagation and material fracture splashing, were quantitatively investigated. The results indicate that the diameter of plasma is proportional to the pulse laser energy and increases linearly during the pulse laser duration with an expansion rate of approximately 6 km/s. The maximum shockwave velocity on the air side is 9 km/s, occurring at the end of the pulse duration, and then rapidly decreases due to air resistance, reaching approximately 1 km/s around a 300 ns delay. After hundreds of nanoseconds, there is a distinct particle splashing phenomenon, with the splashing particle speed distribution ranging from 0.15 km/s to 2.0 km/s. The particle sizes of the splashing particles range from 4 μm to 15 μm. Additionally, the smaller the delay, the faster the speed of the splashing particles. Overall, TRPP technology provides crucial insights into the temporal evolution of laser-induced damage in fused silica, contributing to a comprehensive understanding essential for optimizing the performance and safety of laser systems.

Prediction of Nanoscale Water Meniscus Shape between Deliquescent KDP Crystal Optics and AFM Probe for Water-Dissolution Repairing

KDP (KH2PO4) crystal optics are the key elements for megajoule laser facilities. Nanoscale surface defects would cause laser-induced damage when the optics are irradiated by a high-fluence laser (over 10 J/cm2). Dip-pen nanolithography (DPN) could be used to repair the nanoscale surface defects in the KDP optics by the water meniscus. The high humidity required for high-efficiency and soft KDP surfaces penetrated by the AFM probe brings challenges for accurately predicting the water meniscus shape to evaluate the effectiveness of the DPN water-dissolution repairing. The multisolutions of the Young-Laplace and Kelvin equations also lead to the wrong water meniscus shape. A theoretical model that takes the high humidity and the penetration of the AFM probes into account is developed. The parametrization Young-Laplace equations are adopted for the zero contact angle of the water films, and the AFM probe is treated as the combination of the cone and sphere for the water meniscus whose size is larger than the AFM tip radius under high humidity. The penetration of the AFM probe is modeled by Hertz theory. Both the water films (3.3 nm thickness at 99% relative humidity) and indentations (1.46 nm depth at 300 nN contact force) are non-negligible for the nanoscale water meniscus between the KDP surface and the AFM probe. Moreover, the rough-fine two-step method is proposed to lock the correct solution of the Young-Laplace and Kelvin equations. The effectiveness of the proposed model is verified by comparison with reported ESEM images and pull-off forces. In addition, the overgrowth dots on the KDP surface are compared with the water meniscus. The linear growth of the water meniscus would cause the linear growth of the overgrowth dot, which proves the proposed model could be used to guide the DPN water-dissolution repairing for the nanoscale surface defects in the KDP optics.

Estimation of laser-induced damage depth from surface image features

In laser damage experiments, damage initiation and growth are typically monitored by imaging the surface of the tested fused silica sample, ignoring their bulk morphology. The depth of a damage site in fused silica optics is considered to be proportional to its equivalent diameter. However, some damage sites experience phases with no diameter changes but growth in the bulk independently from their surface. A proportionality relationship with the damage diameter does not accurately describe the growth of such sites. In the following, an accurate estimator for damage depth is proposed, which is based on the hypothesis that the light intensity scattered by a damage site is proportional to its volume. Such an estimator, using the pixel intensity, describes the change of damage depth through successive laser irradiations, including phases in which depth and diameter variations are uncorrelated.

Investigation on hybrid laser ablation and its application in fused silica damage mitigation

We present and investigate a hybrid laser-based method of surface shaping for damage mitigation on fused silica surfaces. Damage sites were removed and precisely shaped into an optically-benign cone by a procedure of femtosecond laser ablation with a subsequent CO₂ laser polishing process. The morphology of the cone rim was quantitatively predicted by a numerical model. Since the heat-affected zone (HAZ) of the laser polishing process was effectively confined by the optimization of ablation parameters, the dimensions of the raised rim were reduced by an order of magnitude. The intensity of the on-axis hotspot was positively related to the dimensions of the raised rim, and thus an inapparent downstream intensification was achieved by the rim reduction. Laser-induced damage threshold (LIDT) of the cone was tested to be ∼14 J/cm² on the input surface. Therefore, the presented method is appropriate to mitigate damage and also provides a promising approach to manufacturing functional microstructures for high-power applications.

Full-scale optic designed for onsite study of damage growth at the Laser MegaJoule facility

Large fusion scale laser facilities aim at delivering megajoules laser energy in the UV spectrum and nanosecond regime. Due to the extreme laser energies, the laser damage of final optics of such beamlines is an important issue that must be addressed. Once a damage site initiates, it grows at each laser shot which decreases the quality of the optical component and spoil laser performances. Operation at full energy and power of such laser facilities requires a perfect control of damage kinetics and laser parameters. Monitoring damage kinetics involves onsite observation, understanding of damage growth process and prediction of growth features. Facilities are equipped with cameras dedicated to the monitoring of damage site growth. Here we propose to design and manufacture a dedicated full size optical component to study damage growth at increased energy, on the beamline, i.e. in the real environment of the optics on a large laser facility. Used for the first time in 2021, the growth statistics acquired by this approach at the Laser MegaJoule (LMJ) facility provides a new calibration point at a fluence less than 5 J cm^-2 and a flat-in-time pulse of 3 ns.

Optical model-based calibration of gray levels for laser damage size assessment

Fused silica is prone to damage under ultraviolet laser irradiation. Because they are key components to achieve fusion on high energy laser facilities, final fused silica optics are analyzed after each laser shot. The quantification of damage sites is limited by the image resolution. Measurements of scattered light by damage sites allow for sub-pixel detection and growth monitoring after a calibration step based on time-consuming measurements at laser facilities. It is proven herein that modeling laser damage size monitoring based on light scattering is efficient to link gray levels to damage diameters, thereby avoiding any experimental calibration based on reference optics at the facility.

Interaction between the mid-infrared continuous wave laser with a center wavelength of 3.8 µm and fused silica

The absorption coefficient of fused silica for a mid-infrared (IR) laser is higher than that for a near-IR laser, but smaller than that for a far-IR laser. Therefore, the energy coupling efficiency of the mid-IR laser is higher than that for the near-IR laser, while the penetration depth is higher than that for the far-IR laser. Thus, the mid-IR laser is highly efficient in mitigating damage growth. In this study, a deuterium fluoride (DF) laser with a center wavelength of 3.8 µm was used to interact with fused silica. The temperature variation, changes in the reflected and transmitted intensities of the probe light incident on the laser irradiation area, and the vaporization and melting sputtering process were analyzed. The results demonstrate that when the laser intensity was low (<1.2 kW/cm²), no significant melting was observed, and the reflection and transmission properties gradually recovered after the end of the laser irradiation process. With a further increase in the laser intensity, the sample gradually melted and vaporized. At a laser intensity above 5.1 kW/cm², the temperature of the sample increased rapidly and vapors in huge quantity evaporated from the surface of the sample. Moreover, when the laser intensity was increased to 9.5 kW/cm², the sample melted and an intense melting sputtering process was observed, and the sample was melted through.

Study on the Repair Technology of Laser Damage-Fused Silica Optics Based on the Neural Network Method

As a key component of a high-power laser device, fused silica optics needs to bear great laser energy, and laser damage is easily generated on the optical surface. In order to improve the service life and availability of optics, it is necessary to repair the damaged optics. In this work, the repair technique of damaged, fused silica optics was studied. The neural network method was mainly used to establish the correlation between the number of small-scale damage points and the repair depth. The prediction accuracy of the model is better than 90%. Based on the neural network model, the removal depth parameters were optimized with the suppression coefficient of the damage points. The processing effect of the optimized parameters was verified by magnetorheological polishing experiments. In this paper, a repair technique based on a neural network was proposed, which avoids the low efficiency caused by processing iterations in the repair process, and can accurately what was expected. The method proposed in this work has an important reference value in the repair process of fused silica optics.

Layer-by-Layer Repair of Small-Scale Damage of Fused Silica Based on the Magnetorheological Method

The magnetorheological (MR) repair method can effectively repair the small-scale damage of fused silica optics and further improve the laser-induced damage threshold of fused silica optics. However, at present, the rules of MR repair of small-scale damage of fused silica are not clear and cannot provide further guidance for the repair process. In this paper, the fused silica damage samples were repaired layer by layer by the MR method. The number and size changes of all the surface damage, the morphology, the fluorescence area distribution, and photothermal-absorption value of a single typical small-scale damage were measured. Through dark field scattering imaging, it is found that when the repair depth is 5 μm, the repair completion rate of damage with a transverse size less than 50 μm can reach 44%, and the repair efficiency decreases gradually with the repair process. Focusing on the whole repair process of a single typical, small-scale damage—due to the flexible shear removal mechanism of the MR method—the repair process of damage can be divided into three stages, which as a whole is a top-down, from outside to inside process. The first stage is the process of removing the surface of the damage layer by layer. In this process, MR fluid will introduce pollution to the inside of the damage. In the second stage, MR fluid begins to repair the inside of the damage. In the third stage, the MR ribbon completely covers the inside of the damage, and the repair effect is the most obvious. The measurement results of photothermal absorption and fluorescence area distribution of damage confirm this process. The photothermal absorption value and fluorescence area distribution of damage do not simply decrease with the repair process. On the contrary, they gradually increase first, and then decrease significantly when the damage depth reaches less than 1 μm. As the thickness of the MR ribbon is 1 μm, the reduction in the photothermal absorption value and fluorescence area of the damage is due to the process of repairing the inside of the damage. The results show that the absorbent impurities inside the small-scale damage of fused silica are the main factor affecting the performance. The key to repairing the small-scale damage of fused silica by the MR method is that the damaged interior must be repaired effectively. This paper outlines the MR repair method of small-scale damage of fused silica, which is of great significance to optimize the MR repair process.

Rapid and Non-Destructive Repair of Fused Silica with Cluster Damage by Magnetorheological Removing Method

The damage repair of fused silica based on the CO₂ laser repair technique has been successfully applied in high-power laser systems in the controllable nuclear fusion field. However, this kind of repairing technique mainly focuses on large-scale laser damage with sizes larger than 200 μm, but ignores the influence of cluster small-scale damage with sizes smaller than 50 μm. In order to inhibit the growth of small-scale damage and further improve the effect of fused silica damage repair, this paper carried out a study on the repair of fused silica damage using the magnetorheological (MR) removing method. The feasibility of fused silica damage repairing was verified, and the evolution law of the number, morphology, and the surface roughness of small-scale damage were all analyzed. The results showed that the MR removing method was non-destructive compared to traditional repairing technologies. It not only effectively improved the whole damage repairing rate to more than 90%, but it also restored the optical properties and surface roughness of the damaged components in the repairing process. Based on the study of the MR removing repair law, a combined repairing process of 4 μm MR removal and 700 nm computer controlled optical surfacing (CCOS) removal is proposed. A typical fused silica element was experimentally repaired to verify the process parameters. The repairing rate of small-scale damage was up to 90.4%, and the surface roughness was restored to the level before repairing. The experimental results validate the effectiveness and feasibility of the combined repairing process. This work provides an effective method for the small-scale damage repairing of fused silica components.

Secondary peak of downstream light field modulation caused by Gaussian mitigation pits on the rear KDP surface

Micro-milling has been proved to be the most effective method to mitigate the growth of laser-induced surface damage on potassium dihydrogen phosphate (KDP) crystals used in high power laser systems. However, the secondary peak of downstream light field modulation caused by Gaussian mitigation pits on the rear KDP surface would cause potential risk to damage downstream optics. In order to explore the effect of the mitigation pits on the secondary peak, we numerically calculated the downstream light field modulations caused by Gaussian mitigation pits on the rear KDP surface based on the angular spectrum diffraction theory. The results suggest that the secondary peaks are dependent on the parameters of the width, depth, depth error and title error. Among them, the tilt error and depth have greater influence on the mitigation effect. To reduce the laser damage risk caused by the secondary peak, the depth of the pre-designed mitigated contour should be optimized according to the actual operating conditions. The tilt error and depth error are proposed to be controlled within 1' and 2 μm, respectively, during the micro-milling. Also, the experiments verified the calculation results of downstream modulations and the effects of these parameters on the secondary peak. This work can not only provide available models for evaluating the laser damage risk of secondary peak caused by mitigation pits on the KDP surface but also contribute to the development of optimal micro-milling parameters for laser damage mitigation as well as the installation strategy of optical components employed in the high power laser systems.

Effect of laser pulse duration and fluence on DKDP crystal laser conditioning

The impact of laser conditioning (LC) fluence and pulse duration on nanosecond (ns) laser damage performance of deuterated potassium dihydrogen phosphate (DKDP) crystal is studied. The result shows that higher LC fluence leads to a better damage resistance. In general, the sub-nanosecond LC effect is better than the nanosecond LC. However, in the range of 0.3 ns to 0.8 ns, the pulse duration has no obvious impact on the LC effect. An ultra-fast process characterization technology is employed to demonstrate that the cleaning effect of the protuberance defects on the surface is one of sub-ns LC mechanism. Eventually, a couple of optimized LC parameters that doubled the maximum damage threshold of DKDP crystal is proposed.

Quantitative Evaluation of Subsurface Damage by Improved Total Internal Reflection Microscopy

Subsurface damage (SSD), having a great impact on the laser-induced damage threshold (LIDT) of ultra-smooth optics applied in high-power laser systems, should be tightly controlled. An improved total internal reflection microscopy (TIRM), combined with digital image processing techniques, is proposed to quantitatively inspect SSD. With the characteristic that there is a relatively small depth of field (DOF) for a microscope at high magnification (50×), a series of SSD images are captured along with the microscope focusing at different depths under the surface by means of micro-focusing control. The definition of each image is calculated through wavelet transformation. By simulation, the relationship between the definition of TIRM images and the depth of the SSD has been established. According to the definition curve, the SSD depth is acquired. Fused silica glasses polished after fine grinding are measured non-destructively by our TIRM setup. The results show that the improved TIRM is a useful method to evaluate SSD. It is helpful to improve the efficiency of optical fabrication.

Hydrofluoric acid-based etching effect on surface pit, crack, and scratch and laser damage site of fused silica optics

In a large-scale, high-power laser facility, fused silica optics plays an irreplaceable role to transmit extremely intense lasers. However, the surface fractures, such as surface pit, crack, and scratch and laser damage site, of fused silica optics will shorten the lifetime of the optics and thus limit the output performance of the laser facility. In this work, besides experimental study, finite difference time domain (FDTD) simulation is performed to study hydrofluoric acid-based (HF-based) etching effect on the surface fractures. The effect of local surface curvature on etching rate is discussed and an explicit local-curvature-dependent etching model is proposed. Based on this model, the result from FDTD simulation qualitatively agrees very well with that of the experiment. It is demonstrated that the FDTD simulation is efficient to predict the morphological evolution of the surface fractures during etching. In addition, it is found that the surface fractures will be passivated and HF-based etching can greatly suppress the laser-damage growth of laser-induced damage to the surface site of fused silica optics.

Plasma-Induced, Self-Masking, One-Step Approach to an Ultrabroadband Antireflective and Superhydrophilic Subwavelength Nanostructured Fused Silica Surface

In this work, antireflective and superhydrophilic subwavelength nanostructured fused silica surfaces have been created by one-step, self-masking reactive ion etching (RIE). Bare fused silica substrates with no mask were placed in a RIE vacuum chamber, and then nanoscale fluorocarbon masks and subwavelength nanostructures (SWSs) automatically formed on these substrate after the appropriate RIE plasma process. The mechanism of plasma-induced self-masking SWS has been proposed in this paper. Plasma parameter effects on the morphology of SWS have been investigated to achieve perfect nanocone-like SWS for excellent antireflection, including process time, reactive gas, and pressure of the chamber. Optical properties, i.e., antireflection and optical scattering, were simulated by the finite difference time domain (FDTD) method. Calculated data agree well with the experiment results. The optimized SWS show ultrabroadband antireflective property (up to 99% from 500 to 1360 nm). An excellent improvement of transmission was achieved for the deep-ultraviolet (DUV) range. The proposed low-cost, highly efficient, and maskless method was applied to achieve ultrabroadband antireflective and superhydrophilic SWSs on a 100 mm optical window, which promises great potential for applications in the automotive industry, goggles, and optical devices.

Understanding the effect of wet etching on damage resistance of surface scratches

Fused silica optics often exhibit surface scratches after polishing that radically reduce their damage resistance at the wavelength of 351 nm in the nanosecond regime. Consequently, chemical treatments after polishing are often used to increase the damage threshold and ensure a safe operation of these optics in large fusion-scale laser facilities. Here, we investigate the reasons for such an improvement. We study the effect of an HF-based wet etching on scratch morphology and propose a simple analytic model to reflect scratch widening during etching. We also use a finite element model to evaluate the effect of the morphological modification induced by etching on the electric field distribution in the vicinity of the scratch. We evidence that this improvement of the scratch damage resistance is due to a reduction of the electric field enhancement. This conclusion is supported by secondary electron microscopy (SEM) imaging of damage sites initiated on scratches after chemical treatment.

Non-destructive evaluation of UV pulse laser-induced damage performance of fused silica optics

The surface laser damage performance of fused silica optics is related to the distribution of surface defects. In this study, we used chemical etching assisted by ultrasound and magnetorheological finishing to modify defect distribution in a fused silica surface, resulting in fused silica samples with different laser damage performance. Non-destructive test methods such as UV laser-induced fluorescence imaging and photo-thermal deflection were used to characterize the surface defects that contribute to the absorption of UV laser radiation. Our results indicate that the two methods can quantitatively distinguish differences in the distribution of absorptive defects in fused silica samples subjected to different post-processing steps. The percentage of fluorescence defects and the weak absorption coefficient were strongly related to the damage threshold and damage density of fused silica optics, as confirmed by the correlation curves built from statistical analysis of experimental data. The results show that non-destructive evaluation methods such as laser-induced fluorescence and photo-thermal absorption can be effectively applied to estimate the damage performance of fused silica optics at 351 nm pulse laser radiation. This indirect evaluation method is effective for laser damage performance assessment of fused silica optics prior to utilization.

Sub-picosecond laser damage growth on high reflective coatings for high power applications

Growth of laser damage on High Reflection (HR) thin film coatings is investigated at the wavelength of 1.030µm in the sub-picosecond regime. An experimental laser damage setup in a pump / probe configuration is used to study the growth behavior of engineered damage sites as well as laser damage sites. Results demonstrate that engineered sites and laser damage sites grow identically which indicates that the growth phenomenon is intrinsic to materials and stack design. In order to analyze the experimental results, we have developed a numerical model to simulate growth. Using FEM simulations, we demonstrate that growth is governed by the evolution of the electric field distribution in the mirror stack under the successive laser shots, which is supported by time-resolved observations of damage growth events. Eventually the results are compared to laser damage observations made on of full scale PETAL mirrors, which fully support the approach.

Optimization of morphological parameters for mitigation pits on rear KDP surface: experiments and numerical modeling

In high power laser systems, precision micro-machining is an effective method to mitigate the laser-induced surface damage growth on potassium dihydrogen phosphate (KDP) crystal. Repaired surfaces with smooth spherical and Gaussian contours can alleviate the light field modulation caused by damage site. To obtain the optimal repairing structure parameters, finite element method (FEM) models for simulating the light intensification caused by the mitigation pits on rear KDP surface were established. The light intensity modulation of these repairing profiles was compared by changing the structure parameters. The results indicate the modulation is mainly caused by the mutual interference between the reflected and incident lights on the rear surface. Owing to the total reflection, the light intensity enhancement factors (LIEFs) of the spherical and Gaussian mitigation pits sharply increase when the width-depth ratios are near 5.28 and 3.88, respectively. To achieve the optimal mitigation effect, the width-depth ratios greater than 5.3 and 4.3 should be applied to the spherical and Gaussian repaired contours. Particularly, for the cases of width-depth ratios greater than 5.3, the spherical repaired contour is preferred to achieve lower light intensification. The laser damage test shows that when the width-depth ratios are larger than 5.3, the spherical repaired contour presents higher laser damage resistance than that of Gaussian repaired contour, which agrees well with the simulation results.

Role of defects in laser-induced modifications of silica coatings and fused silica using picosecond pulses at 1053 nm: II. Scaling laws and the density of precursors

We investigate the role of defects in laser-induced damage of fused silica and of silica coatings produced by e-beam and PIAD processes which are used in damage resistant, multi-layer dielectric, reflective optics. We perform experiments using 1053 nm, 1-60 ps laser pulses with varying beam size, number of shots, and pulse widths in order to understand the characteristics of defects leading to laser-induced damage. This pulse width range spans a transition in mechanisms from intrinsic material ablation for short pulses to defect-dominated damage for longer pulses. We show that for pulse widths as short as 10 ps, laser-induced damage properties of fused silica and silica films are dominated by isolated absorbers. The density of these precursors and their fluence dependence of damage initiation suggest a single photon process for initial energy absorption in these precursors. Higher density precursors that initiate close to the ablation threshold at shorter pulse widths are also observed in fused silica, whose fluence and pulse width scaling suggest a multiphoton initiation process. We also show that these initiated damage sites grow with subsequent laser pulses. We show that scaling laws obtained in more conventional ways depend on the beam size and on the definition of damage for ps pulses. For this reason, coupling scaling laws with the density of precursors are critical to understanding the damage limitations of optics in the ps regime.

Diode-based additive manufacturing of metals using an optically-addressable light valve

Selective Laser Melting (SLM) of metal powder bed layers, whereby 3D metal objects can be printed from a digital file with unprecedented design flexibility, is spurring manufacturing innovations in medical, automotive, aerospace and textile industries. Because SLM is based on raster-scanning a laser beam over each layer, the process is relatively slow compared to most traditional manufacturing methods (hours to days), thus limiting wider spread use. Here we demonstrate the use of a large area, photolithographic method for 3D metal printing, using an optically-addressable light valve (OALV) as the photomask, to print entire layers of metal powder at once. An optical sheet of multiplexed ~5 kW, 20 ms laser diode and ~1 MW, 7 ns Q-switched laser pulses are used to selectively melt each layer. The patterning of near infrared light is accomplished by imaging 470 nm light onto the transmissive OALV, which consists of polarization-selective nematic liquid crystal sandwiched between a photoconductor and transparent conductor for switching.

Particle damage sources for fused silica optics and their mitigation on high energy laser systems

High energy laser systems are ultimately limited by laser-induced damage to their critical components. This is especially true of damage to critical fused silica optics, which grows rapidly upon exposure to additional laser pulses. Much progress has been made in eliminating damage precursors in as-processed fused silica optics (the advanced mitigation process, AMP3), and very high damage resistance has been demonstrated in laboratory studies. However, the full potential of these improvements has not yet been realized in actual laser systems. In this work, we explore the importance of additional damage sources-in particular, particle contamination-for fused silica optics fielded in a high-performance laser environment, the National Ignition Facility (NIF) laser system. We demonstrate that the most dangerous sources of particle contamination in a system-level environment are laser-driven particle sources. In the specific case of the NIF laser, we have identified the two important particle sources which account for nearly all the damage observed on AMP3 optics during full laser operation and present mitigations for these particle sources. Finally, with the elimination of these laser-driven particle sources, we demonstrate essentially damage free operation of AMP3 fused silica for ten large optics (a total of 12,000 cm² of beam area) for shots from 8.6 J/cm² to 9.5 J/cm² of 351 nm light (3 ns Gaussian pulse shapes). Potentially many other pulsed high energy laser systems have similar particle sources, and given the insight provided by this study, their identification and elimination should be possible. The mitigations demonstrated here are currently being employed for all large UV silica optics on the National Ignition Facility.

Scalable process for mitigation of laser-damaged potassium dihydrogen phosphate crystal optic surfaces with removal of damaged antireflective coating

We investigate an approach for the recycling of laser-damaged large-aperture deuterated potassium dihydrogen phosphate (DKDP) crystals used for optical switching (KDP) and for frequency conversion (DKDP) in megajoule-class high-power laser systems. The approach consists of micromachining the surface laser damage sites (mitigation), combined with multiple soaks and ultrasonication steps in a coating solvent to remove, synergistically, both the highly adherent machining debris and the laser-damage-affected antireflection coating. We identify features of the laser-damage-affected coating, such as the "solvent-persistent" coating and the "burned-in" coating, that are difficult to remove by conventional approaches without damaging the surface. We also provide a solution to the erosion problem identified in this work when colloidal coatings are processed during ultrasonication. Finally, we provide a proof of principle of the approach by testing the full process that includes laser damage mitigation of DKDP test parts, coat stripping, reapplication of a new antireflective coat, and a laser damage test demonstrating performance up to at least 12  J/cm² at UV wavelengths, which is well above current requirements. This approach ultimately provides a potential path to a scalable recycling loop for the management of optics in large, high-power laser systems that can reduce cost and extend lifetime of highly valuable and difficult to grow large DKDP crystals.