The bimorph deformable mirror with a diameter of 320 mm, including 127 control electrodes, has been developed and tested. The flatness of the initial mirror surface of about 1 μm (P-V) was achieved by mechanically adjusting the mirror substrate fixed in the metal mount. To correct for the aberrations and improve the beam focusing in the petawatt Ti:Sa laser, the wide-aperture adaptive optical system with the deformable mirror and Shack–Hartmann wavefront sensor was developed. Correction of the wavefront aberrations in the 4.2 PW Ti:Sa laser using the adaptive system provided increases the intensity in the focusing plane to a value of 1.1 × 1023 W/cm2

In this work, two advanced technologies were applied for manufacturing a bimorph wavefront corrector: laser ablation, to vaporize conductive silver coating from piezoceramic surface, and parallel-gap resistance microwelding, to provide a reliable electrical contact between the piezodisk surface silver electrodes and copper wires. A step-by-step guide for bimorph mirror production is presented, together with the ‘bottlenecks’. Optimization of the laser ablation technique was carried out using an Nd:YAG laser with an output power of 4 W and a frequency of 20 kHz. A comparison of the ultrasonic welding and parallel-gap resistance microwelding methods was performed. The tensile strength in the first case was in the range of 0.2…0.25 N for the system ‘copper wire–silver coating’. The use of resistance welding made it possible to increase the value of this parameter for the same contact pair by almost two times (0.45…0.5 N).

Problems of constructing an adaptive optical system intended for correcting the wavefront of laser radiation that has passed through a turbulent atmosphere are considered. To ensure high-quality wavefront correction, the frequency of the discrete system should be at least 1 kHz or more. This performance can be achieved by using FPGA as the main control element of the system. The results of a laboratory experiments of the laser beam phase fluctuations caused by turbulence, produced by the airflow of a fan heater, correction by means of the FPGA-based adaptive optical system are presented. The system efficiency was evaluated at various correction frequencies up to 1875 Hz.

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This paper reports a large-aperture adaptive optical system with a bimorph deformable mirror and Shack?Hartmann wavefront sensor for aberration correction and beam focusing improvement in state-of-the-art petawatt Ti : sapphire lasers. We consider methods for providing feedback to the wavefront sensor and obtaining an objective wavefront that optimises beam focusing onto a target. The use of an adaptive system with a controlled 127-channel 320-mm-aperture mirror in a Ti : sapphire laser with an output power of 4.2 PW has made it possible to obtain a record high laser beam intensity: 1.1 × 1023 W cm-2.

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