Direct numerical simulation of intense laser–solid interactions is still of great challenges, because of the many coupled atomic and plasma processes, such as ionization dynamics, collision among charged particles and collective electromagnetic fields, to name just a few. Here, we develop a new particle-in-cell (PIC) simulation code, which enables us to calculate laser–solid interactions in a more realistic way. This code is able to cover almost ‘all’ the coupled physical processes. As an application of the new code, the generation and transport of energetic electrons in front of and within the solid target when irradiated by intense laser beams are studied. For the considered case, in which laser intensity is $10^{20}~\text{W}\cdot \text{cm}^{-2}$ and pre-plasma scale length in front of the solid is $10~\unicode[STIX]{x03BC}\text{m}$, several quantitative conclusions are drawn: (i) the collisional damping (although it is very weak) can significantly affect the energetic electrons generation in front of the target, (ii) the Bremsstrahlung radiation will be enhanced by 2–3 times when the solid is dramatically heated and ionized, (iii) the ‘cut-off’ electron energy is lowered by an amount of 25% when both collision damping and Bremsstrahlung radiations are included, and (iv) the resistive electromagnetic fields due to Ohmic heating play nonignorable roles and must be taken into account in such interactions.

The Orion facility at the Atomic Weapons Establishment in the United Kingdom has the capability to operate one of its two 500 J, 500 fs short-pulse petawatt beams at the second harmonic, the principal reason being to increase the temporal contrast of the pulse on target. This is achieved post-compression, using 3 mm thick type-1 potassium dihydrogen phosphate crystals. Since the beam diameter of the compressed pulse is ${\sim}600$ mm, it is impractical to achieve this over the full aperture due to the unavailability of the large aperture crystals. Frequency doubling was originally achieved on Orion using a circular sub-aperture of 300 mm diameter. The reduction in aperture limited the output energy to 100 J. The second-harmonic capability has been upgraded by taking two square 300 mm $\times$ 300 mm sub-apertures from the beam and combining them at focus using a single paraboloidal mirror, thus creating a 200 J, 500 fs, i.e., 400 TW facility at the second harmonic.