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We report on the application of the adhesive-free bonding (AFB) technique to form Yb-doped crystalline yttrium aluminum garnet (Yb:YAG) gain media slabs. We performed experiments to characterise mechanical strength, optical quality and laser-induced damage threshold (LIDT) of bonded substrates. We demonstrate that mechanical properties of bonded samples are similar to those of monolithic substrates. We show that the presence of a bonding interface does not introduce unwanted wavefront deformations and does not increase the probability of laser-induced damage onset. Results indicate that the AFB technique constitutes a viable alternative for producing large aperture gain media slabs required for high-energy laser systems.
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