A Laboratory Directed Research and Development Program was conducted with the goal of developing a manufacturing capability for polycrystalline ceramic laser host materials. Polycrystalline transparent ceramics (e.i. Nd:YAG), fabricated by sintering of compacts of fine powder, have been recently shown to have optical properties equal to or better than traditional single crystals with advantages such as improved mechanical properties, increased range of composition and of sample size as well as lower cost. Two materials were studied in this program: Nd:YAG as a baseline material that has potential applications of interest to Sandia such as micro-lasers and graded structures, and Cr,Nd:GSGG whose radiation properties make it suitable for applications such as Direct Optical Initiation. Chemical precipitation synthesis techniques were developed for each material, based on adding metal nitrate solutions to a hydroxycarbonate precipitant solution, to produce nano-size powders with controlled and uniform stoichiometry that could be readily crystallized to the desired garnet phase. The crystalline powders were then milled ultrasonically and formed into compacts by vacuum filtration of aqueous particle suspensions that had uniform packing of the powder with minimal contamination and other defects. Sintering and uniaxial hot-pressing studies were than carried out on the powder compacts. Sintering studies on both powders showed that they commenced densification at ~1200 C and could reach nominally 100% of theoretical density after sintering at or below 1500 C for several hours. Sintering the Nd:YAG by heating directly to higher temperatures, >1650 C, produced transparent samples that contained large pores. Sintering studies showed that pore growth mechanisms were responsible for the presence of the large pores and a multi-stage sintering approach was used to avoid large pore formation. Although samples of Cr,Nd:GSGG were sintered essentially pore-free, they remained only translucent. Transparent samples, not of laser quality, were also produced of both materials by uniaxial hot-pressing. Even though the ultimate goal of laser quality transparent ceramics was not obtained, significant progress towards developing the entire fabrication process for such materials was made and the level of understanding achieved shows what direction to follow for further improvements in optical properties.
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ACKNOWLEDGEMENTS