Welded Optics Mounts for Lasers and OPOs

Our goal under the combined Phase I - Phase II program would be to deliver an OPO-based system demonstrated to meet Air Force requirements in an extreme environment. Under this Phase I project, we would characterize a new technique for optics mounting which we expect to lead to improved robustness and manufacturability of lasers. This technique is electrical resistance spot-welding. We have recently demonstrated three-point spot welds with a pull strength of over 1 kilogram. We would completely characterize the spot-welding process, and compare it to other processes for the permanent mounting of optics. We would measure the characteristics of each mounting technique, and would choose an optimum technique. Alignment tolerances, alignment stability, part and labor cost, capital cost, and outgassing of components would all be quantified. Under the Phase II program, we would build an OPO with a robust design. The optics mounting techniques developed in Phase I would be used. This OPO would be tested, and would then be subjected to vibration and thermal cycling, and then retested. The ultimate outcome of the Phase I - Phase II program would be a design of a rugged and robust laser for Air Force use.