Semiconductor Laser Diodes (LDs) generate high output powers with high power conversion efficiencies. While broad-area LDs are favored for high-power applications, narrow-waveguide LDs are in demand for their single-mode characteristics. However, LDs suffer from device failures caused by Catastrophic Optical Damage (COD) due to elevated self-heating at high operating currents. It is critical to understand the COD mechanism in these devices to enhance their reliability and operating output power. In this study, we investigated the self-heating and temperature characteristics of LDs with varying waveguide widths to uncover the cause of their failure mechanism. We assessed the performance, junction, and facet temperatures of the narrow (W=7 μm) and broad waveguide (W=100 μm) LDs. The narrower waveguide LDs achieved and operated at higher output power densities but, surprisingly, maintained lower junction and facet temperatures. Additionally, we employed a thermal simulation model to analyze heat transport characteristics versus LD waveguide widths. The simulation results showed that narrower waveguide LDs exhibit improved three-dimensional heat dissipation, resulting in reduced junction and facet temperatures and, thus, enhanced reliability. Our simulations align well with the experimental data. The findings demonstrate a transition in heat dissipation characteristics from broad to narrow waveguide behavior at approximately 50 μm width. These results clarify the fundamental reasons behind the superior reliability of narrower waveguide LDs and provide valuable guidance for LD thermal management.
Catastrophic optical mirror damage (COMD) limits the output power and reliability of laser diodes (LDs). The self-heating of the laser contributes to the facet temperature, but it has not been addressed so far. This study investigates a two-section waveguide method targeting significantly reduced facet temperatures. The LD waveguide is divided into two electrically isolated sections along the cavity: laser and passive waveguide. The laser section is pumped at high current levels to achieve laser output. The passive waveguide is biased at low injection currents to obtain a transparent waveguide with negligible heat generation. This design limits the thermal impact of the laser section on the facet, and a transparent waveguide allows lossless transport of the laser to the output facet. Fabricated GaAs-based LDs have waveguide dimensions of (5-mm) x (100-μm) with passive waveguide section lengths varied from 250 to 1500 μm. The lasers were operated continuous-wave up to the maximum achievable power of around 15 W. We demonstrated that the two-section waveguide method effectively separates the heat load of the laser from the facet and results in much lower facet temperatures (Tf). For instance, at 8 A of laser current, the standard laser has Tf = 90 °C, and a two-section laser with a 1500 μm long passive waveguide section has Tf = 60 °C. While traditional LDs show COMD failures, the multi-section waveguide LDs are COMD-free. Our technique and results provide a pathway for high-reliability LDs, which would find diverse applications in semiconductor lasers.
Catastrophic optical mirror damage (COMD) limits the output power and reliability of lasers diodes (LDs). Laser self heating together with facet absorption of output power cause the facet to reach a critical temperature (Tc), resulting in COMD and irreversible device failure. The self-heating of the laser contributes significantly to the facet temperature, but it has not been addressed so far. We implement a multi-section waveguide method where the heat is separated from reaching the output facet by exploiting an electrically isolated window. The laser waveguide is divided into two electrically isolated laser and transparent window sections. The laser section is pumped at high current levels to achieve laser output, and the passive waveguide is biased at low injection currents to obtain a transparent waveguide with negligible heat generation. Using this design, we demonstrate facet temperatures lower than the junction temperature of the laser even at high output power operation. While standard LDs show COMD failures, the multi-section waveguide LDs are COMD-free. Our technique and results provide a pathway for high-reliability LDs, which would find diverse applications in semiconductor lasers
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