J. Decker

High-Power Distributed Feedback Lasers With Surface Gratings: Theory and Experiment

Semiconductor lasers with integrated surface gratings are known to operate with narrow spectra as well as high power and efficiency. In this paper, we present a theoretical description of DFB lasers with 80th-order waveguide gratings, fabricated by etching narrow grooves into the epitaxial layer structure. The passive gratings are simulated by mode expansion and S-matrix algorithm yielding the reflection and transmission matrices in dependence on wavelength for given parameters of the grating, such as residual layer thickness and width of the grooves. The lasing condition is solved by constructing a round-trip operator and singular-value deposition for the calculation of lasing wavelength and threshold gain. A fast simulation of DFB lasers is performed within the framework of coupled-wave theory using adapted coupling coefficients. GaAs based ridge-waveguide and narrow-stripe broad-area lasers with integrated surface gratings are experimentally shown to emit output powers of 0.6 W into a single spectral line ΔλFWHM <; 30 pm) and > 5 W into a spectrum with width Δλ95% ≈ 0.8 nm, respectively.

25-W Monolithic Spectrally Stabilized 975-nm Minibars for Dense Spectral Beam Combining

Low-fill-factor laser bars composed of five narrow-stripe broad-area lasers (30 μm × 6000 μm) with monolithic spectral stabilization are presented. Each laser on the bar emits at a unique wavelength from 970 to 980 nm with a channel spacing of 2.5 nm. Narrow spectral line width c1 nm per emitter is obtained by implementing 40th Bragg order distributed feedback surface gratings with varied grating periods. The design and fabrication of these laser bars is reviewed, with optimal grating etch depth determined using simulations that combine 2D-simulation of the reflectivity and optical losses of a 40th-order surface grating with coupled mode theory. The selected etch depth delivers a grating coupling coefficient of κL ~ 0.2, which is shown to be sufficient to suppress lasing in Fabry-Perot modes for narrow line operation across all wavelength channels. However, additional optical scattering losses of the gratings are found to limit output power and efficiency. The final realized minibars deliver 25-W continuous wave output power with a conversion efficiency >40% and operate with a beam parameter product of ~1.6 mm mrad per single emitter, twofold improved in comparison with typical 90-μm wide broad area laser. Such laser minibars are an attractive source for brilliant dense spectral beam combining.

Separate phase-locking and coherent combining of two laser diodes in a Michelson cavity

We describe a new coherent beam combining architecture based on passive phase-locking of two laser diodes in a Michelson external cavity on their rear facet, and their coherent combination on the front facet. As a proof-of-principle, two ridge lasers have been coherently combined with >90 % efficiency. The phase-locking range, and the resistance of the external cavity to perturbations have been thoroughly investigated. The combined power has been stabilized over more than 15 min with an optical feedback as well as with an automatic adjustment of the driving currents. Furthermore, two high-brightness high-power tapered laser diodes have been coherently combined in a similar arrangement; the combining efficiency is 70% and results in an output power of 4 W. We believe that this new configuration combines the simplicity of passive self-organizing architectures with the optical efficiency of master-oscillator power-amplifier ones.

Development of high-power diode lasers with beam parameter product below 2 mm×mrad within the BRIDLE project

High power broad-area diode lasers are the most efficient source of optical energy, but cannot directly address many applications due to their high lateral beam parameter product BPP = 0.25 × ΘL 95%× W95% (ΘL95% and W95% are emission angle and aperture at 95% power content), with BPP > 3 mm×mrad for W95%~90μm. We review here progress within the BRIDLE project, that is developing diode lasers with BPP < 2 mm×mrad for use in direct metal cutting systems, where the highest efficiencies and powers are required. Two device concepts are compared: narrow-stripe broad-area (NBA) and tapered lasers (TPL), both with monolithically integrated gratings. NBAs use W95% ~ 30 μm to cut-off higher order lateral modes and reduce BPP. TPLs monolithically combine a single mode region at the rear facet with a tapered amplifier, restricting the device to one lateral mode for lowest BPP. TPLs fabricated using ELoD (Extremely Low Divergence) epitaxial designs are shown to operate with BPP below 2mm×mrad, but at cost of low efficiency (<35%, due to high threshold current). In contrast, NBAs operate with BPP < 2 mm×mrad, but maintain efficiency >50% to output of > 7 W, so are currently the preferred design. In studies to further reduce BPP, lateral resonant anti-guiding structures have also been assessed. Optimized anti-guiding designs are shown to reduce BPP by 1 mm×mrad in conventional 90 μm stripe BA-lasers, without power penalty. In contrast, no BPP improvement is observed in NBA lasers, even though their spectrum indicates they are restricted to single mode operation. Mode filtering alone is therefore not sufficient, and further measures will be needed for reduced BPP.

High power surface-grating stabilized narrow-stripe broad area lasers with beam parameter product < 2 mm×mrad

Narrow-stripe (30 μm aperture) broad area lasers with monolithically integrated DFB-surface-gratings deliver 5 W optical output per emitter with 50% conversion efficiency, spectral width ≤ 1 nm from 970…980 nm, and beam parameter product < 2 mm×mrad.

High-power operation of coherently coupled tapered laser diodes in an external cavity

We demonstrate a rear-side phase-locking architecture with two high-brightness diode lasers. This technique is based on the passive phase-locking of emitters in an external cavity on their rear facet, and their coherent combination on the front facet. Two high-brightness high-power tapered laser diodes are coherently combined using a Michelson-based cavity. The combining efficiency is above 80% and results in an output power of 6.7 W in a nearly diffraction-limited beam. The rear-side architecture is then used with a laser bar of 5 tapered emitters using an interferometric extended cavity, based on a diffractive optical element. We describe the experimental evaluation of the diffractive optical element, and the phase-locked operation of the laser bar.

Novel approaches to increasing the brightness of broad area lasers

Progress in studies to increase the lateral brightness Blat of broad area lasers is reviewed. Blat=Pout/BPPlat is maximized by developing designs and technology for lowest lateral beam parameter product, BPPlat, at highest optical output power Pout. This can be achieved by limiting the number of guided lateral modes and by improving the beam quality of low-order lateral modes. Important effects to address include process and packaging induced wave-guiding, lateral carrier accumulation and the thermal lens profile. A careful selection of vertical design is also shown to be important, as are advanced techniques to filter out higher order modes.

Rear-side resonator architecture for the passive coherent combining of high-brightness laser diodes

We describe a new coherent beam combining architecture based on passive phase locking of emitters in an extended cavity on the rear facet and their coherent combination on the front facet. This rear-side technique provides strong optical feedback for phase locking while maintaining a high electrical-to-optical efficiency. Two high-brightness high-power tapered laser diodes are coherently combined using a Michelson-based cavity. The combining efficiency is above 82% and results in an output power of 6.7 W in a nearly diffraction-limited beam with an M(4σ)(2)≤1.2. A semi-active automatic adjustment of the current enhances the long-term stability of the combination, while the short-term stability is passively ensured by the extended cavity. This new laser configuration exhibits the simplicity of passive self-organizing architectures while providing a power conversion efficiency of 27% that is comparable to master oscillator power amplifier architectures.

Narrow-stripe broad-area lasers with distributed-feedback surface gratings as brilliant sources for high power spectral beam combining systems

Laser systems based on spectral beam combining (SBC) of broad-area (BA) diode lasers are promising tools for material processing applications. However, the system brightness is limited by the in-plane beam param- eter product, BPP, of the BA lasers, which operate with a BPP of < 3mm-mrad. The EU project BRIDLE (www.bridle.eu) is developing novel diode laser sources for such systems, and several technological advances are sought. For increased system brightness and optimal ber-coupling the diode lasers should operate with reduced BPP and vertical far eld angle (95% power content), μV 95. The resulting diode lasers are fabricated as mini- bars for reduced assembly costs. Gratings are integrated into the mini-bar, with each laser stripe emitting at a different wavelength. In this way, each emitter can be directed into a single bre via low-cost dielectric filters. Distributed-feedback narrow-stripe broad-area (DFB-NBA) lasers are promising candidates for these SBC sys- tems. We review here the design process and performance achieved, showing that DFB-NBA lasers with stripe width, W = 30 μm, successfully cut of higher-order lateral modes, improving BPP. Uniform, surface-etched, 80th-order Bragg gratings are used, with weak gratings essential for high e ciency. To date, such DFB-NBA sources operate with < 50% effciency at output power, Pout < 6 W, with BPP < 1.8 mm-mrad and offV 95 36 . The emission wavelength is about 970 nm and the spectral width is < 0.7 nm (95% power). The BPP is half that of a DFB-BA lasers with W = 90 um. We conclude with a review of options for further performance improvements.

Non-uniform DFB-surface-etched gratings for enhanced performance high power, high brightness broad area lasers

Monolithic spectral stabilization is demonstrated in narrow-stripe broad-area lasers (NBA) with high power (5W), conversion efficiency (50%) and high brightness, by using optimized high-order surface-etched DFB gratings. However, surface etched gratings introduce a high index contrast into the semiconductor, leading to the scattering losses increasing rapidly with groove etch depth, limiting efficiency and yield. We therefore review progress in the exploitation of novel, non-uniform grating configurations for improved performance. Devices with non-uniform gratings whose groove etch depth decreases toward the front facet (apodized grating) are shown to operate with enhanced spectrally stable power (6W) compared to devices with uniform gratings.