Open Access Article
Federico
Giulio
*,
Luca
Calciati†
,
Filippo
Andreotti
,
Andrea
Brevi
and
Dario
Narducci
Department of Materials Science, University of Milano-Bicocca, Via Roberto Cozzi 55, 20125, Milano, Italy. E-mail: federico.giulio@unimib.it
First published on 25th November 2025
Metal-Assisted Chemical Etching (MACE) using Ag as the catalyst lets prepare vertically aligned crystalline silicon nanopillars (SiNPs), a highly promising system for thermoelectric applications, with high aspect ratios in a wide doping range. MACE may be implemented either by using Ag both as the catalyst and the oxidant (so-called one-pot MACE) or by using another chemical (typically H2O2) as the oxidant (two-pot MACE). This study investigates how the localized etching rate depends upon Si doping in both MACE implementations, accounting for the concurrent non-catalyzed etching. The latter, which shortens SiNPs, is found to become more significant in p-type Si at higher doping levels due to the narrower space-charge regions at the bare Si-solution interface. We demonstrated that in both one- and two-pot MACE the etching rate is controlled by the band bending at silicon–silver interface. In p-type silicon, it decreases with doping due to faster hole diffusion, while the Schottky barrier at the interface hinders hole injection in n-type silicon at any doping level. Overall, we highlight that MACE may be effectively implemented in its one-pot version, facilitating MACE scale-up toward SiNP large-scale manufacturing.
Several techniques have been exploited to produce SiNPs, both bottom-up and top-down,17 including Vapor–Liquid Solid,18 Molecular Beam Epitaxy19 and cryogenic Reactive Ion Etching.20 However, they all require ultra-high-vacuum conditions, which severely limit their scalability. Additionally, the growth rate is low, also often resulting in low density SiNPs.21
Metal-Assisted Chemical Etching (MACE) provides a remarkable alternative, as it enables SiNP to be obtained at room temperature and ambient pressure with high densities, very high aspect ratios and excellent crystalline quality.22 Moreover, MACE allows full control of SiNP orientation and, in principle, lets obtain SiNPs of arbitrary length. The technique is based on the local silicon oxidation catalyzed by metallic nanoparticles, which can be generated either in situ from a metallic salt or deposited via physical methods.23 More specifically, when the metal acts both as the catalyst and the oxidant (e.g. using Ag/Ag+) the procedure is referred to as one-pot MACE. Instead, when the metal is used only as the catalyst while the oxidation is carried out by a different chemical (e.g. H2O2), it is known as two-pot MACE. blueOne-pot MACE is a simpler technque, as it does not require multiple solutions, thereby minimizing processing time and cost. In contrast, the two-pot MACE process follows a sequential approach, in which the catalyst nanoparticles are deposited on the Si surface (by either physical or chemical methods) prior to the etching step, at the cost of greater complexity. However, two-pot MACE offers greater versatility, as the pattern of metal nanoparticles can be tailored to produce different nanostructures such as nanosheets or nanorods.23 Both in one- and two-pot MACE, the etch rate depends on several parameters, including temperature,24 illumination,25 concentration of the oxidizing agent and of HF,9,26 metal catalyst and the shape of its nanoparticles.27,28 Moreover, the etch rate exhibits a stronger dependence on both silicon dopant type and concentration and, since MACE is a technique amenable to be brought to industrial production grade, it is essential to achieve full control over the etch rate for different types of silicon. The aim of this paper is to investigate how Si doping level and type impact MACE etch rate where Ag is used as the catalyst, for both one- and two-pot processes. Numerous studies in the literature have investigated the influence of silicon dopant type and level on the etch rate in MACE. Lai et al.29 studied two-pot MACE using gold as a catalyst and H2O2 as the oxidizing agent. They reported that the etch rate decreases with increasing dopant concentration for p-type silicon, while, for n-type silicon, it remains nearly constant with increasing phosphorus concentration. This behavior was attributed to the formation of Schottky barriers. Similarly, Ohlin et al.30 demonstrated that under the same MACE conditions (gold and H2O2), n-type silicon etches faster than p-type silicon at the same doping level. Backes et al.31 explored two-pot MACE using silver as a catalyst. Their results show a decrease in the etch rate with increasing doping level for p-type silicon, confirming their previous results,32 while for n-type silicon, the etch rate remains constant at low and medium doping levels. They explain these trends with the presence of Schottky barrier in n-type silicon that trapped the carrier at the interface, while in p-type silicon the etch rate is ruled by the carrier diffusion away from the metal semiconductor interface. In contrast to the above findings, Bagal et al.33 observed an increase of the etch rate with doping level for both n-type and p-type silicon when using silver and H2O2, suggesting a different doping-dependence trend under their conditions. Further supporting this observation, Li et al.34 reported a decrease in the etch rate for n-type silicon with increasing doping concentration using silver as the catalyst. Interestingly, they noted that this trend reversed when accounting for the effects of lateral etching because of the dissolution and re-nucleation of metallic silver. To the best of our knowledge, instead, no detailed study has reported the etch rate of one-pot MACE as a function of silicon doping level and type. We will show that the etch rate dramatically changes moving from n- to p-type silicon, in striking contrast with what is observed for non-catalyzed etching. Charge injection and accumulation/depletion at the relevant interface between metal, silicon, and the electrolytic solution are shown to rule the etch rate.
| Type | Dopant | Resistivity (Ω cm) | Doping level (cm−3) | Thickness (μm) |
|---|---|---|---|---|
| p− | B | 11.6 | 1.3 × 1015 | 660 |
| p | B | 0.7 | 2.5 × 1016 | 450 |
| p+ | B | 0.02 | 4.0 × 1018 | 525 |
| n− | P | 6.1 | 7.4 × 1014 | 280 |
| n | P | 0.08 | 1.1 × 1017 | 380 |
| n+ | P | 0.003 | 2.0 × 1019 | 500 |
The samples were prepared with the following procedure: Silicon chips (1.5 × 0.5 cm2) were cleaved from [100]-oriented p- and n-type silicon substrates. The samples were cleaned using ammonium-peroxide solution (1
:
1
:
5 NH3 (29% vol.)
:
H2O2 (33% vol.)
:
H2O)36 at 65 °C for 15 minutes and then rinsed in deionized (DI) water, removing all organic contaminants. Samples were then immediately soaked in the MACE solution. For one-pot MACE, AgNO3 (16 mM) and HF (5 M) were used. Instead, for two-pot reaction, the samples were firstly immersed in a solution containing AgNO3 (5 mM) and HF (5 M) for 1 minute and then rinsed in DI water. Afterward, the silver-coated samples were immersed in the etching solution (H2O2, 0.4 M + HF, 8 M). For both processes the temperature was kept constant at 20 °C with a thermostatic bath. For all silicon samples, in both one- and two-pot MACE, etching occurred on both sides of the wafer, resulting in a double NP forest. At the end of the MACE processes the samples were immediately soaked in DI water to stop the reaction and then in a solution containing HNO3 (32% vol.) for 15 minutes to remove silver dendrites and nanoparticles, then rinsed in DI and finally dried using a nitrogen flux. SiNP length and morphology were evaluated by Scanning Electron Microscopy (SEM). SEM analyses were performed with a ThermoFisher Phenom G6 SEM, equipped with a thermionic emission source. This instrument achieves a resolution <6 nm at 15 kV using a Everhart–Thornley type detector for secondary electrons.
![]() | ||
| Fig. 1 Cross section SEM images of n− SiNPs obtained after 2-pot MACE reaction at differing etching time: 96 min (a), 192 min (b) 330 min (c) and 370 min (c). | ||
To obtain a proper estimate of the MACE rate, one should consider that, in addition to MACE, etching also occurs on the bare Si surface, including SiNP tips. We will refer to this non-localized etching as overetching. Therefore, in what follows we first measured the dependence of overetching rate and its variation upon doping level and type; then, after measuring the apparent MACE rate, we corrected it accounting for the tip removal by overetching.
By measuring the total thickness of the obtained samples, which includes the SiNP forests and the silicon layer beneath them, it is evident that the etched samples have a reduced thickness compared to the pristine silicon wafer (Fig. 2). This thickness loss was observed for both MACE processes and for both doping types.
Thickness loss is evaluated as the difference between the pristine wafer thickness and the thickness of the samples, after MACE processes, for different reaction times. By plotting the thickness loss as a function of the reaction time, the overetching rate can be determined from the slope of the resulting line. The overetching rate as a function of the doping level for both n- and p-type silicon, and for both MACE processes, is reported in Fig. 3.
Overetching is more relevant in two-pot MACE than in one-pot and, moreover, the higher the doping level the higher the overetching rate for both p- and n-type substrates.
Two effects concur to such difference. From SEM analyses (Fig. 4) one observes the occurrence of etching pits on the tips and on the sidewalls of the wires. The formation of these additional localized etching sites arises from the reoxidation of metallic silver, with Ag+ subsequently undergoing reduction back to metallic silver. The redeposited Ag preferentially accumulates in energetically favorable regions and defects-rich sites such as the tips or walls of the nanopillars.41
Such silver shuttling is more pronounced in two-pot MACE. Indeed, in this case, silver nanoparticles located at the bottom of the bores can be oxidized by the hydrogen peroxide, which has a more positive redox potential than the Ag+/Ag couple (0.80 V and 1.78 V vs. SHE, respectively), and re-nucleate on the sidewall, reducing the effective length of the SiNPs.42
Silver shuttling is detectable also in one-pot MACE but the presence of the dendritic structures, which completely overfill the bores, partially hinders it, leading to a smaller thickness loss. Moreover in one-pot MACE the species that can re-oxidize silver is water, a weaker oxidant compare to hydrogen peroxide. Furthermore, in both one- and two-pot MACE, the presence of defects is higher in more heavily doped substrates, further promoting the formation of lateral etching sites,43 in accordance with measured overetching rates (Fig. 3).
The second process that contributes to the thickness loss is the non-localized etching, basically the direct hole exchange between solution and silicon that occurs everywhere on the bare silicon surface. Non-localized etching always takes place and competes with localized etching, being eventually dominant,11,44 and occurs both in one- and two-pot MACE.
To better understand non-localized etching and its relation with silicon doping level, the interface between silicon and the oxidant solution is analyzed (Fig. 5 and Fig. S4).
In all cases, once contact is established and equilibrium conditions are reached, Fermi level of the semiconductor aligns with the redox potential of the oxidizing couple.45,46 In one-pot MACE the interface is ruled by the Ag+/Ag potential (Fig. 5) while in two-pot is determined by the H2O2/H2O redox potential (Fig. S4). Since both the potential of Ag+/Ag and H2O2/H2O are more negative than the Fermi energies (Tables S1 and S2), bands always bend upward. Potential drop occurs almost entirely at the semiconductor side. In all cases, a potential barrier is formed at the silicon/solution interface. Thus, the injection of holes, from the solution into the valence band, and, consequently, their diffusion into the silicon bulk is hindered, leading to hole accumulation in the space-charge region near the silicon surface. The thickness of this space-charge region depends on the doping level and on the oxidizing strength of the redox couple. Specifically, the region narrows as the doping level increases. This is clearly noticeable in both Fig. 5 and S4. Indeed, in one-pot MACE the space-charge region in p−-type is approximately 800 nm wide, while in p+-type is just 20 nm. A similar trend is observed for n−-type silicon (≈1250 nm versus ≈12 nm in n+-type) as shown in Fig. 5. Same behaviour can be observed in two-pot MACE for both silicon types (Fig. S4). Since the etching rate is correlated with the hole density near the silicon surface, a narrower space-charge region leads to a more pronounced overetching. This competes with localized etching, resulting in a more significant loss of thickness. Consequently, non-localized etching is more prominent at higher doping levels, because the accumulation region is only a few tens of nanometers thick. In contrast, in lightly doped silicon, the accumulation region is wider, allowing diffusion of holes from the surface into the silicon bulk. This makes non-localized etching less effective, favouring the formation of SiNPs.
| Ag(aq)+ → Ag(s) + h+ E° = +0.79 V vs. NHE | (1) |
In this way metallic silver particles are deposited onto silicon surface and holes are injected into silicon valence band. Over time, these particles evolve in complex dendritic structures reaching a height of several microns. The dendrimers completely overfill the etching bores.24 In the meantime, oxidation of silicon takes place. Two competing anodic reactions concurrently occur:11,26 the first reaction is called 4-electron process and is the reaction ruling silicon electropolishing.47 Silicon is directly oxidized to Si4+:
![]() | (2) |
| SiO2(s) + 6HF(aq) → SiF6(aq)2− + 3H3O+ | (3) |
The alternative oxidation path is known as 2-electron process. In this case, silicon is initially oxidized to Si2+:
![]() | (4) |
Then Si2+ is oxidized to Si4+ with the concurrent reduction of two hydronium ions to molecular hydrogen:
| SiF4(aq)2− + 2HF(aq) → SiF6(aq)2− + H2(g) | (5) |
The 4-electron reaction is dominant for low-doped silicon substrates. In this case the oxide dissolution is the slow reaction step, leading to a smooth and regularly etched silicon surface or, when localized, to the formation of single-crystalline SiNPs. Vice versa, on highly doped silicon, 2-electron process prevails, the oxide elimination being the fast reaction step that leads to the formation of a porous silicon layer or, when localized, to (partially) porous SiNPs.24
Two-pot MACE occurs instead in two different steps.48 First of all, the deposition of catalytic metallic nanoparticles takes place. This step could be performed either via chemical reduction of metallic cations in solution or by using physical methods like evaporation or sputtering. The second step is the silicon oxidation in a solution containing both the oxidant and HF. Typically, hydrogen peroxide (H2O2) is used as oxidant. Hydrogen peroxide injects holes into silicon according to the reaction:26
![]() | (6) |
Oxidation of silicon and the oxide etching follow either the 4-electron or the 2-electron path, as in one-pot MACE.
Since the chemistry of one- and two-pot MACE is the same, one expects that etch rates should be comparable in the two processes. By plotting the SiNP lengths as a function of reaction time, the apparent localized etch rate for each doping level is obtained (Fig. 6), along with the effective etch rates. The latter was computed by taking into account the NP thickness loss due to overetching (Fig. 7). Essentially, the effective etch rate is the etch rate in the absence of overetching. As expected the effective etch rates are higher. The largest increase in the effective etch rate is noticeable for the highly doped samples. Nonetheless, in n-type samples, for both the one- and two-pot processes, the effective etch rate remains almost constant, confirming no dependence on the doping level. Instead, for p-type samples, the higher the doping level the lower the etch rate for both MACE processes.
Etch rate for p− and p samples is similar, while at higher doping level it suddenly decreases for both one- and two-pot MACE. In contrast, in n-type samples the etch rate remains almost constant with varying doping levels. Thus, no qualitative difference in localized etch rate is observed between one-pot and two-pot MACE. Moreover, the SEM images in Fig. 1 and S1 show no noticeable morphological differences between the NPs obtained by one- and two-pot MACE.
To understand the different etching behaviour between n- and p-type silicon one should consider the interface between silicon and the catalytic metal (Fig. 8 and Fig. S3). When silver enters in intimate contact with silicon, Fermi level aligns with the metal work function, leading to a band bending in the semiconductor side – and to a potential drop thereof. The extent of band bending depends on the Fermi levels of the semiconductor (set by its doping level and type) and on the metal work function (4.26 eV for polycristalline silver24) (Fig. 8). This is manifestly the same in both one and two-pot MACE since bending depends solely on the relative position of the Fermi level and the silver work function, which are not affected by the oxidant species. Thus, the localized etch rate is ruled by the silicon/silver interface.
For all doping level the presence of metallic silver pins the Fermi energy and the band folds downward. Thus, no potential barrier hindering hole injection into the valence band and their diffusion toward silicon bulk is present. According to Lai et al.,29 who observed similar results in two-pot MACE using gold as a catalyst, in p-type silicon the absence of a potential barrier means that the concentration of holes is ruled by their drift velocity away from the interface. The drift velocity, in turn, depends both on the hole mobility and on the electric field strength at the interface. As doping increases, mobility decreases while the electric field increases, since at higher doping level the space-charge region narrows, dropping from ≈900 nm in p− samples to ≈300 nm in p samples and to just ≈33 nm in p+ Si. Therefore, p− and p samples exhibit similar drift velocities and, as a result, comparable etch rates. Instead, in p+ silicon, the electric field strength becomes dominant, compensating for the reduced mobility. Thus, holes move away from the interface, causing a lower etch rate.
In the case of n-type silicon (Fig. S3), while for lightly doped samples there is a slight downward band bending, in samples with higher doping levels, the bands bend upwards, displaying the formation of a potential barrier at the silver/silicon interface. The barrier, in the case of n and n+ Si, opposes to the injection of holes into silicon valence band confining the holes near the interface. Consequently, the etch rate is similar regardless of the doping level.
It is worth mentioning that when the silicon/silver system is immersed in the solution, another interface is also formed, namely the one between silver and the electrolyte solution. The potential drop that occurs at the interface can be computed using the classical metal/solution interface and can be described with the standard electrical double layer model.49 However, the calculated potential drop at the Ag/electrolyte interface is significantly smaller than that at the Si/Ag interface and therefore does not affect the silicon band bending and does not play a relevant role in the MACE mechanism. This is in agreement with literature reports.45,46 Further details on the band bending calculations and interface modeling are reported in the SI.
When analyzing the effective etch rate, which includes losses due to overetching, no substantial difference is observed between one-pot and two-pot MACE. This indicates that the etching is primarily governed by the silicon/silver interface through the doping level and type of the semiconductor. In p-type silicon, where silver does not form a Schottky barrier, the etch rate decreases with doping concentration due to the fast hole diffusion away from the interface. In highly doped p-type samples the reduction in hole mobility is compensated by the increased electric field strength at the interface, resulting from the narrower space charge region compared to low-doped samples. This stronger field accelerates hole drift away from the interface, preventing effective participation in the etching reaction and thus reducing the etch rate. In contrast, for n-type silicon, the presence of a Schottky barrier at the interface hinders hole injection, resulting in an etch rate largely independent of doping level. These findings are in agreement with Lai et al.29 and Backes et al.31,32 who observed similar results in two-pot using both gold and silver as catalyst. Notably, our study extends this understanding to include one-pot MACE, showing that even with different oxidant environments, the same doping-dependent trends hold on, confirming the key role of the silicon/silver interface in governing the etch rate.
In conclusion, this study provides deeper insight into the fundamental mechanisms governing MACE for different doped silicon type. By demonstrating that the etch rate is ruled by interfacial processes at the silicon/silver junction, rather than by the type of MACE process, we simplify the choice between one-pot and two-pot strategies for various applications. This flexibility is particularly valuable for scalable manufacturing of SiNPs. Additionally, the role of overetching is highlighted as a critical factor affecting final SiNP length, especially in highly doped silicon.
Supplementary information (SI) is available. See DOI: https://doi.org/10.1039/d5nr03474d.
Footnote |
| † Present address: Department of Environmental Sciences, Informatics and Statistics, Ca' Foscari University of Venice, Via Torino 155, 30170, Venezia Mestre, Italy. |
| This journal is © The Royal Society of Chemistry 2025 |