Open Access Article
Li
Jiang
ab,
Jianwei
Ben
*b,
Ke
Jiang
b,
Shanli
Zhang
b,
Tong
Wu
b,
Zikai
Nie
bd,
Entao
Zhang
bc,
Shunpeng
Lu
b,
Xiaojuan
Sun
*b and
Dabing
Li
*abc
aSchool of Microelectronics, University of Science and Technology of China, Hefei, Anhui 230026, People's Republic of China
bState Key Laboratory of Luminescence Science and Technology, Changchun Institute of Optics, Fine Mechanics and Physics, Chinese Academy of Sciences, Changchun 130033, China. E-mail: benjianwei@ciomp.ac.cn; sunxj@ciomp.ac.cn; lidb@ciomp.ac.cn
cUniversity of Chinese Academy of Sciences, Beijing 100039, People's Republic of China
dSchool of Integrated Circuits, Dalian University of Technology, Dalian 116024, China
First published on 9th April 2025
The thickness and surface morphology of aluminum nitride (AlN) templates are crucial for evaluating their quality and suitability for device applications. However, the relationship between these two factors remains unclear for AlN templates grown via magnetron sputtering. This study systematically investigates the surface restructuring mechanisms in AlN films during thickness progression, revealing a stress-driven morphological transition. As film thickness increases, accumulated tensile stress exceeding ∼0.5 GPa triggers the spontaneous formation of “flower-like” surface patterns through stress relief. While mitigating further stress buildup, this morphological transformation degrades crystalline quality post-high-temperature annealing. Through strategic optimization of sputtering thermodynamics, we successfully preset compressive stress in AlN films and extended the critical thickness for morphological degradation to 2 μm. The resulting high-quality thick AlN films exhibit simultaneously improved surface continuity and enhanced crystalline perfection. These results provide valuable insights into the stress-morphology interactions in sputtered AlN films, offering new strategies for optimizing AlN template growth and enhancing the performance of AlN-based devices.
The thickness and surface morphology of AlN films are critical, as they directly affect the electronic and optical properties of the material, thereby influencing device performance. For instance, in AlN-based SAW devices, film thickness and processing conditions play a significant role in determining frequency response, operational speed, and insertion loss.15–17 Moreover, researchers have prepared AlN films with different surface structures by chemical vapor deposition (CVD), molecular beam epitaxy (MBE) and other methods. They found the structural variations significantly influence the physical and chemical properties of AlN by introducing defects, such as carbon (C) and oxygen (O) impurities and vacancies of aluminum (Al) and nitrogen (N).18–20 Therefore, the ability to produce smooth AlN films with precise control over thickness is essential for optimizing the performance of the aforementioned devices.
Among the various fabrication methods, magnetron sputtering is one of the most widely adopted techniques, offering high uniformity and low impurity content. Extensive research has been conducted to investigate the surface evolution of AlN films fabricated by magnetron sputtering. Studies indicate that surface morphology, roughness, and other properties are sensitive to sputtering conditions, including temperature, nitrogen flow ratio, and sputtering power.21–25 Researchers have also explored the effects on the crystal orientation, defects, and device performance of AlN films by adjusting magnetron sputtering parameters (substrate material, substrate angle, nitrogen ratio, sputtering power, etc.).26–29 High c-axis-oriented AlN films have been successfully grown using unbalanced magnetron sputtering, which utilizes an asymmetric magnetic field to enhance ion bombardment. This approach facilitates the formation of denser grains, reduces surface roughness, and improves crystal quality.30 Furthermore, film thickness plays a crucial role in determining the microstructure and defect characteristics of AlN films. Longer sputtering time increases the grain size and roughness. However, as film thickness increases, the AlN film becomes denser, with a gradual transition in orientation from disordered to well-ordered AlN (002) planes.31,32 These findings emphasize the critical importance of controlling film thickness to enhance crystal quality and minimize defect density.
Despite these advancements, the mechanisms by which film thickness influences surface morphology evolution remain inadequately understood. In this work, we employ reactive magnetron sputtering to deposit AlN films and systematically investigates the relationship between film thickness and surface morphology evolution. It has been demonstrated that when the film thickness surpasses a critical threshold, a distinct “flower-like” morphology emerges, coinciding with stress relaxation within the film. This morphology increases surface roughness and degrades crystal quality due to elevated grain boundary content and defect density. The research further reveals that the critical thickness for the onset of “flower-like” morphology can be effectively increased from 800 nm to over 2 μm by raising the sputtering temperature from 650 °C to 750 °C. This temperature adjustment enhances film quality and surface smoothness, providing valuable insights into the interplay between stress and surface morphology.
:
N2 (10%
:
90%) mixed atmosphere at different temperatures (650 °C, 700 °C, 750 °C), the average growth rate of AlN growth at 650 °C, 700 °C, 750 °C are 0.2484 nm s−1, 0.2437 nm s−1, 0.2387 nm s−1, respectively, which are similar.
High-resolution X-ray diffraction (XRD: D8 Discover) was used to characterize the crystal quality (dislocation density) of the AlN film. Scanning electron microscopy (SEM: S-4800) and atomic force microscopy (AFM: MULTIMODE 8) were used to characterize the surface morphology of the sample. Raman spectroscopy (Omni-λ3008i) was used to characterize the stress of the sample.
The cross-sectional SEM shows that the “flower-like” morphology exhibits a conical structure, with the apex of the cone growing between the columnar crystals. The base of the cone starts approximately 800 nm to 1 μm away from the substrate, which is consistent with the critical thickness at which the “flower-like” morphology first appears. Moreover, all the conical structures have the similar apex angle, approximately 46° (half of the angle of the conical structure is about 23° ± 2°), as indicated in Fig. 1(e)–(g). To investigate whether the “flower-like” morphology corresponds to a special crystal orientation, the wide range (10–80°) XRD 2Theta-Omega measurements were performed on AlN samples with varying thicknesses as shown in Fig. S1.† It was found that there is only the peak of (0002) plane AlN for all the samples, although the “flower-like” morphology have fully covered the surface of AlN with 2 μm thickness. Additionally, AFM measurements were performed on samples with different thicknesses, revealing that the “flower-like” structures are about 40 nm higher than the columnar structures, with the center of the “flower-like” features being lower than the surrounding areas. The details are shown in Fig. S2.† Moreover, as the film thickness increases, the surface roughness also increases. The presence of “flower-like” morphology greatly increases the roughness of the surface. The surface roughness of samples with different thicknesses is listed in Table S1.†
From the surface characterization results shown in Fig. 1, it can be observed that as the thickness of sputtered AlN templates increases, the grain size generally increases. According to published research, the merging of columnar structures will introduce tensile stress to the film.33 To investigate the stress of the samples with different thicknesses and morphologies, Raman measurements were used to characterize the stress. Since the surface morphology varies across different regions of the samples, Raman mapping was conducted to ensure the reliability of the stress results as exhibited in Fig. S3.† They present uniform stress distribution throughout the AlN film, which can confirm the reliability of the stress characterization in Fig. 2. The Raman spectra for AlN samples of different thicknesses are shown in Fig. 2(a), with a zoomed-in view of the AlN E2(high) peak shown in Fig. 2(b), because the E2(high) peak is commonly used to calculate the stress in AlN films. As the film thickness increases, the peak position exhibits an initial redshift followed by stabilization. The stress magnitude can be calculated using the formula:33
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To further investigate the interplay between surface morphology and stress, an experiment was designed with the goal of changing the stress state during film growth in order to control the surface morphology. During experiments, we found that the stress can be adjusted by changing the sputtering temperature. As shown in Fig. 3(a)–(c), as the temperature increased from 600 °C to 750 °C, the tensile stress of 200 nm AlN film decreased from 0.29 GPa to −2.35 GPa. Increasing the sputtering temperature can reduce the tensile stress (introduce compressive stress), resulting in a lower tensile stress in AlN films with the same thickness. This effectively increases the critical thickness of the threshold tensile stress and the appearance of “flower-like” morphology, enabling the growth of thicker AlN films with superior surface morphology. Therefore, we raised the sputtering temperature to 700 °C and grew AlN films of varying thicknesses. The surface morphology and stress variations of the samples were measured, with stress characterization results shown in Fig. 3(d)–(f). The tensile stress gradually increases for films with thicknesses ranging from 800 nm to 1.4 μm. However, beyond 1.4 μm, the tensile stress decreases, indicating a release of tensile stress. The critical thickness at which the stress reaches saturation was delayed to 1.4 μm. Fig. 4(a)–(e) show the SEM surface morphologies of samples with different thicknesses at 700 °C. The results indicate that the critical thickness for the appearance of the “flower-like” morphology increased to 1.4 μm, which corresponds to the critical thickness where the stress reaches a stable value. This validates the conclusion that the appearance of the “flower-like” morphology is due to the alleviation of the continuously accumulating tensile stress. By increasing the sputtering temperature to 750 °C, the critical thickness for morphological degradation can be further delayed from 1.4 μm to 2 μm. These results demonstrate that the stress state during the film growth process is one of the key factors influencing the surface morphology of the film.
High-temperature annealing (HTA) is considered an effective method for improving the crystallinity of AlN films.35 In the process of HTA, the columnar domains will coalesce and the domain boundaries in AlN films annihilate, resulting in improved crystal quality.36–38 To further investigate the influence of the “flower-like” morphology on the quality of AlN films with/without annealing, samples with the same thickness but different surface morphologies were selected for high-temperature face-to-face annealing (1700 °C in N2 atmosphere under normal pressure for 1 h). One sample, exhibiting a “flower-like” morphology, was sputtered at 650 °C (as shown in Fig. 1(f)), while the other, without “flower-like” morphology, was sputtered at 750 °C (as shown in Fig. 4(f)). X-ray rocking curve (XRC) analysis was performed with and without annealing, and the results are shown in Fig. 5. With high-temperature annealing, the sample with “flower-like” morphology shows a reduction in the full width at half maximum (FWHM) of the X-ray rocking curve (XRC) for the (0002)/(10–12) planes from 810/1857.6 arcsec to 558/910.8 arcsec, those of the sample without “flower-like” morphology decrease from 399.6/1256.4 arcsec to 313.2/522 arcsec. These results indicate that the presence of the “flower-like” morphology negatively affects the quality of HTA-AlN films. Notably, the (0002) and (10–12) planes are associated with screw dislocations and edge dislocations, respectively. The screw dislocation density and edge dislocation density of AlN films are calculated as:39,40
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| Fig. 5 XRC of the (0002) and (10–12) planes for 2 μm samples at different sputtering temperatures. (a and b) without annealing. (c and d) With 1700 °C annealing. | ||
Fig. 6 shows the SEM surface and cross-sectional morphology of the two samples with annealing. The results indicate that numerous voids will appear in these two samples, which are consistent with previous research.41 For HTA-AlN with “flower-like” morphology, the voids are located at the interfaces between the layers of the “flower-like” structure from the plane view of SEM, as shown in Fig. 6(a). The SEM cross-sectional view further highlights the conical arrangement of the voids, as indicated in Fig. 6(b). The largest voids are found at the outermost edges of the “flower-like” morphology, where they intersect with the columnar structure. The SEM plane and cross-sectional views of HTA-AlN without “flower-like” morphology are shown in Fig. 6(c) and (d), respectively. It can be found that in the HTA-AlN with “flower-like” morphology, the voids within the “flower-like” structures exhibit both larger dimensions and higher density compared to the HTA-AlN without “flower-like” morphology. Additionally, these voids are concentrated near the upper surface of the sample, particularly at the interface between the “flower-like” morphology and the columnar structure. According to the analysis of void formation mechanisms, it is understood that the generation of voids with high-temperature annealing in AlN films is primarily due to the high grain boundary density and defect density, which confirms that the material properties in the “flower-like” morphology are distinct from those in the columnar region. The multi-layer, conical structure of the “flower-like” morphology leads to a high concentration of grain boundaries, which promotes the formation of a large number of voids and defects with annealing. In addition, the initially better quality AlN before HTA do not lead to better quality HTA-AlN as discussed in Fig. S5,† which supporting the conclusion that the “flower-like” morphology is harmful to obtain high quality HTA-AlN films. Therefore, the presence of the “flower-like” morphology negatively impacts the film quality. The increased sputtering temperature reduces the film's tensile stress during growth, optimizing the surface morphology and simultaneously improving the crystalline quality of the film.
Footnote |
| † Electronic supplementary information (ESI) available. See DOI: https://doi.org/10.1039/d5ce00027k |
| This journal is © The Royal Society of Chemistry 2025 |