Design and characterization of "flow-cell" integrated-flow active cooling for high-average-power ceramic optics

Area of Science:

• Materials Science
• Optical Engineering
• Thermal Management

Background:

• High-average-power laser systems require advanced thermal management solutions.
• Existing substrates may face limitations in handling intense optical loads.
• Novel materials and designs are crucial for improving laser performance and longevity.

Purpose of the Study:

• To design and test a novel actively cooled flow-cell substrate for high-average-power laser applications.
• To evaluate the thermal performance and laser-induced damage threshold of a cordierite ceramic substrate.
• To validate simulation predictions with experimental results for optical component design.

Main Methods:

• Utilized COMSOL Multiphysics for the design of an actively cooled flow-cell substrate.
• Fabricated the prototype substrate using cordierite ceramic material.
• Conducted thermal loading tests and sub-aperture testing to assess power handling.
• Performed laser-damage threshold testing on gratings fabricated on cordierite coupons.

Main Results:

• The actively cooled flow-cell substrate demonstrated average-power handling up to 3.88-W/cm² absorbed power density.
• Experimental results showed excellent agreement with COMSOL Multiphysics model predictions.
• Gratings on cordierite coupons exhibited a laser-induced damage threshold of 250 mJ/cm².

Conclusions:

• The designed cordierite ceramic flow-cell substrate is suitable for high-average-power laser applications.
• The study validates the effectiveness of active cooling and material selection for thermal management in lasers.
• The findings provide valuable data for the development of robust optical components in demanding laser environments.