Ceramic laser materials have come a long way since the first demonstration of lasing in 1964. Improvements in powder synthesis and ceramic sintering as well as novel ideas have led to notable achievements. These include the first Nd:yttrium aluminum garnet (YAG) ceramic laser in 1995, breaking the 1 KW mark in 2002 and then the remarkable demonstration of more than 100 KW output power from a YAG ceramic laser system in 2009. Additional developments have included highly doped microchip lasers, ultrashort pulse lasers, novel materials such as sesquioxides, fluoride ceramic lasers, selenide ceramic lasers in the 2 to 3 μm region, composite ceramic lasers for better thermal management, and single crystal lasers derived from polycrystalline ceramics. This paper highlights some of these notable achievements.

In this review, we present our recent research progress at the Naval Research Laboratory in the development of highly transparent and rugged ceramic window materials such as ${\mathrm{MgAl}}_2{\mathrm{O}}_4$ spinel and $\beta$-SiC; high-power solid-state laser gain materials based on sesquioxide such as ${\mathrm{Yb}}^{3+}\text{:}{\mathrm{Y}}_2{\mathrm{O}}_3$, ${\mathrm{Yb}}^{3+}\text{:}{\mathrm{Lu}}_2{\mathrm{O}}_3$, and ${\mathrm{Ho}}^{3+}\text{:}{\mathrm{Lu}}_2{\mathrm{O}}_3$; and composite ceramics in the application for high-energy lasers. Various powder synthesis/purification methods and powder post-process techniques necessary to create high-purity powders are described. Ceramic fabrication processes and chemical, morphological, and optical properties of the ceramics developed at the Naval Research Laboratory (NRL) are highlighted. We also report high-efficiency lasing from a hot-pressed rare-earth sesquioxide single layer and composite ceramics made from coprecipitated powder.

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High purity Yb3+ doped Lu2O3 powder has been synthesized by the co-precipitation method. The powders underwent a jet milling at various feed rate using a commercial jet mill machine. It is found that jet milling is very effective in breaking up of large agglomerates without cross-contamination. Median agglomerate size decreased from 8.74 μm to 1.06 μm when jet milled at a feed rate 0.75 lb/hr. There was no noticeable increase in impurities picked up during the jet milling process in the final powder obtained after a sacrificial run that was carried out for the purpose of conditioning the surface of the liner. Homogeneous, uniform, and highly transparent ceramic was obtained from the ceramic hot pressed with the final jet milled powder compared to the one made from as-produced powder where some defects and splotches are often observed. Transmission of the Yb3+:Lu2O3 ceramics obtained from the jet milled powder is very close to the theoretical limit, demonstrating the excellent quality of the transparent ceramic.

We present a method of Cu(In,Ga)S₂ (CIGS) thin film formation via conversion of layer-by-layer (LbL) assembled Cu-In-Ga oxide (CIGO) nanoparticles and polyelectrolytes. CIGO nanoparticles were created via a novel flame-spray pyrolysis method using metal nitrate precursors, subsequently coated with polyallylamine (PAH), and dispersed in aqueous solution. Multilayer films were assembled by alternately dipping quartz, Si, and/or Mo substrates into a solution of either polydopamine (PDA) or polystyrenesulfonate (PSS) and then in the CIGO-PAH dispersion to fabricate films as thick as 1–2 microns. PSS/CIGO-PAH films were found to be inadequate due to weak adhesion to the Si and Mo substrates, excessive particle diffusion during sulfurization, and mechanical softness ill-suited to further processing. PDA/CIGO-PAH films, in contrast, were more mechanically robust and more tolerant of high temperature processing. After LbL deposition, films were oxidized to remove polymer and sulfurized at high temperature under flowing hydrogen sulfide to convert CIGO to CIGS. Complete film conversion from the oxide to the sulfide is confirmed by X-ray diffraction characterization.