High power pulsed magnetron sputtering (HPPMS) processes, including its potential application in interconnect metallization during microfabrication, require a precise control of fluxes and energies of various plasma species. A more fundamental understanding of the pulsed discharge mechanisms and the underlying physics thus becomes necessary. In a 36 cm planar magnetron system, a triple Langmuir probe was used to study the time-resolved behaviors of the HPPMS plasma under various discharge and pulsing parameters, as well as at different positions extending from the target surface. The pulsed plasma was shown to be established through multiple stages. And the 3-dimensional probe characterization depicted a scenario of plasma expansion from the plasma-confined racetrack, producing high density peaks up to 10¹⁹ m^-3 into the pulse-off period. The delay time of these peaks from the pulse-off edge varied from several to several hundred µs with different probe positions, and was found to depend on the plasma density in the racetrack which affects the diffusion constant, and the temporal location of the peak plasma density in the racetrack as well. In addition to the probe measurements in the vicinity of the racetrack, a special setup with quartz crystal microbalance and current collecting plate behind orifices drilled in the target was designed. Ion fluxes to the cathode were directly measured, while the metal ion and argon ion fluxes were distinguished time-averagely. The self-sputtering theory of HPPMS is supported by a higher metal ion fraction measured at a higher pulse peak current. Based on the above experiments, a 1-dimensional time-dependent HPPMS discharge model was developed incorporating the surface reactions, ionization process in the plasma, and plasma diffusion. It was able to describe the essential processes of plasma buildup and dispersion, and to predict some important plasma properties such as density and ionization fraction from the basic inputs of magnetic field, discharge and pulsing parameters, etc.

High power impulse magnetron sputtering, HiPIMS, has been the source of significant scientific interest in recent years. HiPIMS consists of a high voltage / high current pulse, followed by a long off-period resulting in low duty cycles. In the present study additional control parameters are explored by using non-standard HiPIMS waveforms, consisting of pulse sequences. These pulse sequences consist of a number of micro-pulses, which can be varied in length. In a further novel approach to HiPIMS, the pulses were also applied in a bi-polar manner, with a positive voltage supplied to the same target between negative voltage pulses. Films have been grown using varied pulse sequences, in both uni- and bi-polar mode, and compared to materials grown both by traditional, single pulse, HiPIMS and dcMS.The deposition of Ti metal was chosen as a model system, and the attained coatings were analysed using X-ray diffraction, XRD, scanning electron microscopy, SEM, and X-ray photoelectron spectroscopy, XPS. An increased deposition rate, relative to a comparable standard HiPIMS pulse, was observed. The coating microstructures show increased smoothening of the coating surface and shallower surface oxidation for samples deposited using micro-pulsed HiPIMS.

Molybdenum oxide, a material prized for its ability to facilitate thermochromism and electrochromism, has displayed considerable sensitivity to oxygen concentrations present during reactive DC magnetron sputtering. Typical depositions performed using continuous reactive DC magnetron sputtering have demonstrated low deposition rates and limited control over stoichiometry as a result of oxygen induced target poisoning. In the following study, molybdenum oxide films were deposited using reactive modulated pulse power magnetron sputtering (MPPMS) using a 99.999% pure molybdenum sputtering target within an argon-oxygen atmosphere. At a pressure of 10 mTorr, the oxygen concentration was varied between 1 and 20%. The resulting films were characterized by way of in-situ spectroscopic ellipsometry, x-ray photoelectron spectroscopy, x-ray diffraction and UV-visible spectroscopy. The as-deposited films were determined to be amorphous by way of x-ray diffraction analysis and were analyzed without any prior heat treatment. In-situ spectroscopic ellipsometry was conducted throughout the deposition process, monitoring real time changes in the refractive index, extinction coefficient and thickness of the film.

In the field of hard and wear-resistant coatings, thin films based on the system aluminium and chromium represent the state of the art. With the addition of nitrogen and/or oxygen ceramic coatings covering a wide compositional range can be synthesised. In the present study, a time-of-flight spectrometer was used to investigate the arc plasma composition in terms of elemental and ion charge state composition when using Al_xCr_1-x (0≤x≤1) composite cathodes in different gaseous environments, i.e. in vacuum as well as argon, nitrogen and oxygen atmosphere. The observed ion distributions were interpreted in the established framework of plasma generation at cathode spots and ion-gas interactions.