Modeling of residual tool mark formation and its influence on the optical performance of KH₂PO₄ optics repaired by micro-milling

In the micro-milling repair process of surface defects on KH₂PO₄ (KDP) optics, residual tool marks are inevitably introduced on repaired surfaces. These tool marks could present great potential risks in lowering laser-induced damage thresholds of repaired KDP optics, which has not been reported in the previous works. In this work, the formation process of micro-milled tool marks was initially modeled and then the effect of these residual marks on the optical performance of KDP optics was investigated theoretically and experimentally. A 3D surface generation model for repair contours is proposed to predict the profiles of residual tool marks on micro ball-end milled surfaces, and then a numerical FEM model adopting the calculated profiles of residual tool marks is established to investigate the light intensification inside KDP optics based on electromagnetic theory. The relationship between repair machining processes, tool marks profiles and light intensifications as well as laser damage resistance of repaired KDP optics, has been discussed comprehensively and systematically. Practical repair experiments and laser damage tests verified the theoretical results very well. It revealed that the residual height of tool marks can induce apparent diffraction effect, consequently causing severe light intensification inside KDP optics. The micro milling strategies (e.g. a combination of layer-milling and spiral milling paths) can also exert a positive role in improving the laser damage resistance of KDP optics. An optimized repair process flow, adopting layer-milling path as rough milling and employing spiral-milling with path intervals of 10~15 μm as fine milling, is recommended for the future practical engineering repair of full-aperture KDP optics in ICF facilities.