ICMCTF2011 Session B1-2: PVD Coatings and Technologies

Tuesday, May 3, 2011 1:30 PM in Room Royal Palm 1-3

Tuesday Afternoon

Time Period TuA Sessions | Abstract Timeline | Topic B Sessions | Time Periods | Topics | ICMCTF2011 Schedule

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1:30 PM B1-2-1 Growth Morphology and Corrosion Resistance of Magnetron Sputtered Cr Films
Kuang-Tsan Chiang, Ronghua Wei (Southwest Research Institute)
Chromium films are commonly used as corrosion resistant coatings because they form a passive, protective scale. The film morphology and microstructure are important aspects of corrosion resitance. In this paper, we presented grwoth mechanisms and morphologies of these films to provide insight into the microstructural properties of corrosion resistance. Thin films of Cr were deposited on silicon wafer, copper and carbon steel substrates using a plasma-enhanced magnetron sputtering technique. A filament was utilized to produce a plasma that effects an ion bombardment on the workpiece during the magnetron sputter deposition process. The deposited fims were characterized by x-ray diffraction, scanning electron microscopy and atomic force microscopy. The film growth morphology and microstructure are correlated with sample orientation (with respect to the magnetron) and the deposition parameters. On important deposition parameter affecting Cr film properties is the level of plasma ion bambardment. It has been demonstrated that at a low level of ion bombardment, a columnar structure is formed and film is discontiguous. As the level of ion bombardment increases, the film become denser and contiguous. Eventually the film becomes fully dense without indication of columnar structure. The corrosion behavior of the deposited films was studied using potentiodynamic polarization techniques. It has been demonstrated that adequate ion bombardment is necessary to achieve the required corrosion resistance.
1:50 PM B1-2-2 Fundamental Studies on the Deposition of Nanocrystalline Diamond (n-D) Films by Means of Pulsed Laser Deposition
Hagen Grüttner (Hochschule Mittweida - University of Applied Sciences, Germany)

The results of fundamental studies on the deposition of nanocrystalline diamond (n-D) films by means of pulsed laser deposition (PLD) will be present. The n-D films were deposited on silicon (111) and hard metal by excimer laser ablation from a graphite target at elevated substrate temperatures and in hydrogen background gas. The variation of the microstructure and the properties of the films with temperature was investigated in the range of 100°C to 660°C and with hydrogen pressure in the range of 1 mbar to 7 mbar. With diamond and / or ion bombardment pretreated and non-pretreated substrates were used and the influence of the pretreatment process on the microstructure of the films was investigated. The films were produced at laser fluences between 10 J/cm² and 15 J/cm². The thickness of the films was varied from 100 nm up to 2 microns. The influence of deposition parameters on the n-D growth and the sp2/sp3 bonding ratio was determined by Raman spectroscopy and TEM / EELS analysis and it will be shown that n-D films of good quality can be prepared using proper parameters. The hardness and Young´s modulus were determined using nanoindentation and the optical properties in the UV / VIS range was measured by using photospectrometry. The variation of these properties with deposition parameters and their correlation with the microstructure of the n-D films will also be presented.

2:10 PM B1-2-3 Oxidation and Degradation of Nitride Thin Films at High Temperature under Controlled Atmosphere
Fu-Hsing Lu (National Chung Hsing University, Taiwan)
Oxidation and degradation of nitride thin films, such as TiN, CrN, ZrN, AlN, prepared by magnetron sputtering were investigated over various temperatures in different atmospheres by analyzing changes in appearance and crystalline phases, as well as microstructures. The atmospheres contained air, nitrogen, and forming gas (N2/H2 = 9), which exhibited drastically different nitrogen and oxygen partial pressures. Oxidation of the nitride films was driven by the Gibbs free-energy changes between the nitrides and the formed oxides, and could be tailored by controlling the annealing temperature and nitrogen/oxygen partial pressures. Both internal stresses resulted from sputtering and thermally-induced stresses were responsible for many types of degradation in the films, which would be further discussed.
2:50 PM B1-2-5 Effects of Pulsed Laser Irradiation of As-Deposited c-BN-Films using Photons of 157 nm Wavelength
René Bertram (Hochschule Mittweida - University of Applied Sciences, Germany)

We present the effects of pulsed laser irradiation of as-deposited c-BN-films using photons of 157 nm wavelength and 7.9 eV energy, respectively. The films were deposited by pulsed laser deposition (PLD) using a KrF excimer laser of 248 nm wavelength and up to 30 J/cm2 laser fluence on the pyrolytic hexagonal boron nitride target with additional ion beam bombardment of the growing films using a mixture of nitrogen and argon ions produced in a r.f. ion source with 700 eV ion energy.

The irradiation of such coatings with a fluorine laser was found to influence the number and size of sp2-bonded hBN particulates and thus the further cBN growth as well as the sp3 / sp2 ratio.

So, alternating deposition of sub-layers and irradiation directly affects the quality of the entire c-BN films.

Furthermore, calculations were done concerning the mean penetration depth of the photons in the c-BN films and, based on these evaluations of laser-induced temperature fields, experiments have been carried out using proper sub-layer thickness. The influence of the irradiation of the films with photons on the intrinsic shear stresses, which limited the film thickness so far, was investigated and will be presented.

3:10 PM B1-2-6 High Power Impulse Magnetron Sputtering of Niobium in Non-Reactive and Reactive Gas Environments
Rueben Mendelsberg, Sunnie Lim, KinMan Yu, Andre Anders (Lawrence Berkeley National Laboratory)

High power impulse magnetron sputtering (HIPIMS) is a young technology whose opportunities, advantages and limitations are currently intensely investigated by a number of groups. Here we selected niobium as one of the most interesting materials since thin films of niobium and niobium compounds are used in a diverse range of applications. Pure niobium films are needed for the next generation of superconducting radio-frequency cavities not made from solid niobium. Niobium nitride is a material sometimes incorporated in hard, wear-resistant coatings and multilayers for its added corrosion resistance benefit. Niobium oxide is an attractive high index material for optical and photonics applications. The complex refractive index can be tuned by going to niobium oxynitride. We report on the dramatic changes of the HIPIMS discharge behavior when going from pure metal mode to reactive deposition, and correlate some plasma and film properties. One could expect that HIPIMS with other transition metals exhibit similar features.

Work supported by the U.S. Department of Energy under Contract No. DE-AC02-05CH11231.

3:30 PM B1-2-7 Barrier Capability of Reactively Sputtered TaxZr1-xN Films with Slight Ta Addition Against Copper Diffusion
Jian-Long Ruan, Jow-Lay Huang (National Cheng Kung University, Taiwan); Horng-Hwa Lu (National Chin-Yi University of Technology, Taiwan); Jen-Sue Chen (National Cheng Kung University, Taiwan); Ding-Fwu Lii (Cheng Shiu University, Taiwan)
The TaxZr1-xN films were prepared by reactive magnetron sputtering and the concentration of zirconium and tantalum was regulated by controlling the power of the sputtering guns. A sputter-prepared Cu (100 nm)/TaxZr1-xN (5 nm)/SiO2 (100 nm)/Si stacked structure was fabricated for the evaluation of diffusion barrier performance of TaxZr1-xN films. The composition, microstructure, resistivity and diffusion barrier properties of TaxZr1-xN films were studied by x-ray diffraction, electron probe microanalyzer, Auger electron spectroscopy, and four point probe method. Results indicated that the slight addition of Ta (3.5 at. %) could effectively further decrease the electrical resistivity of films to a value of 78 μΩ-cm compared with pure ZrN films due to the extra d valence electron of Ta comparing with Zr. Auger electron spectroscopy and sheet resistance measurements showed that the slight incorporation of Ta (3.5 at. %) into the ZrN films significantly improved the barrier performance against Cu diffusion. In addition, the TaxZr1-xN films with 3.5 at. % of Ta could be successfully used as a diffusion barrier layer between Cu and SiO2 even up to the high temperature of 800°C for 5 minutes in a vacuum, while the ZrN films failed at the same temperature.
3:50 PM B1-2-8 The Influence of Substrate Biasing on the Crystal Orientation of γ-Al2O3 Films
Marina Prenzel, Tim Baloniak, Annika Kortmann, Teresa de los Arcos, Achim von Keudell (Ruhr-Universität Bochum, Germany)
Substrate biasing is an established technique to control and adjust material properties during thin film deposition from a plasma. The external bias voltage manipulates the energy distribution function of the ions impinging on the substrate (IEDF). An optimized ion bombardment can significantly improve for example film hardness, adhesion, crystallinity, or wear resistance.

Here, we report on the influence of sinus RF biasing at 1 MHz on the crystallinity of aluminium oxide films. The films are prepared in a RF magnetron discharge, which is excited by 13.56 and 71 MHz frequencies and used for reactive sputtering of an aluminium target. The target is mounted on the powered electrode and the silicon substrate is placed on a biased electrode at the opposite side. The temperature of the substrate is varied and reaches up to 700°C. A feedback loop based on measurements of an Al-atom emission line is used to control the partial pressure of O2 in the plasma.

The Al2O3 films are characterized by FTIR, XPS and XRD. During this study, a combination of arbitrary function biasing scheme and IEDF measurements with a retarding field analyzer has been performed. The results reveal a dependence of the orientation of the crystal structure in the film on the energy distribution of the ions. First results show that the orientation of the crystal structure can be manipulated by the variation of bias voltage. In future, these results are planned to optimize the Al2O3 deposition process and to reveal the role of the ion energy in the film growth. The work is funded by DFG within SFB-TR 87.

4:10 PM B1-2-9 Target Erosion Effects in Reactive Pulsed DC Magnetron Sputtering of Amorphous and Crystalline Alumina
NisDam Madsen, Sascha Louring, AndersNørløv Berthelsen (Aarhus University, Denmark); Bjarke Holl Christensen, Klaus Pagh Almtoft, Lars Pleth Nielsen (Danish Technological Institute, Tribology Centre, Denmark); Jørgen Bøttiger (Aarhus University, Denmark)
Alumina coatings were synthesized by reactive pulsed DC magnetron sputtering in an industrial-scale deposition system. The aim of this study was to investigate the influence of target erosion (racetrack depth) on the structural and mechanical properties of the alumina coatings. Hysteresis curves, showing the cathode voltage as function of oxygen flow, were mapped out for several target erosion depths. Each deposition was made with a fixed cathode voltage and the current was controlled by adjusting the oxygen flow in a feedback loop by means of which a constant power was maintained. Keeping the power constant, this procedure was repeated for various cathode voltages within the hysteresis transition region and at different deposition temperatures. The corresponding deposition rates were observed to depend mainly on the relative position of the cathode voltage on the hysteresis curve, and to a lesser degree the absolute cathode voltage. Coatings deposited at low temperatures (~200˚C) were amorphous, as evidenced by X-ray diffraction (XRD), but the films exhibited morphological changes with varying racetrack depth. Nanoindentation revealed hardness and reduced elastic-modulus values of 9 Gpa and 160-165 Gpa, respectively, regardless of the target erosion and the cathode voltage. However, at deposition temperatures around 550˚C, there were dramatic changes in the mechanical properties as a function of the cathode voltage within the hysteresis transition region but also due to changes in the racetrack depth. The changes in mechanical properties, e.g. hardness from 9 Gpa to 20 Gpa, was due to the deposited films changing from amorphous to crystalline.

4:30 PM B1-2-10 Thermal Stability of Magnetron Sputtered Alumina Coatings with Crystalline Metastable Structure
Petr Zeman, Sarka Proksova, Jakub Blazek, Radomir Cerstvy, Jindřich Musil (University of West Bohemia, Czech Republic)
Machining of materials with low thermal conductivity, such as stainless steel or nickel superalloys, demands to use cutting tools with an enhanced performance. Crystalline alumina coatings with high hot hardness and high chemical inertness are promising candidates. Present trends in the research of crystalline alumina coatings include two areas. One of them is the deposition of pure α-Al2O3 coatings at temperatures as low as possible (≤ 700°C ) and another one is the deposition of metastable γ-Al2O3 coatings with thermal stability as high as possible. The present study extends knowledge in thermal stability of magnetron sputtered alumina coatings containing the crystalline γ-phase. Special attention is devoted not only to the effect of the temperature necessary for the γ-to-α transformation but also to the effect of the time during isothermal heating near the transformation temperature. Kinetic analysis of the γ-to-α transformation was also studied in detail. The crystalline alumina coatings sputtered in an argon‑oxygen mixture at selected process parameters using a dual magnetron system equipped with two aluminum targets were investigated by means of differential scanning calorimetry and symmetrical high-resolution thermogravimetry. The structure of the coatings was characterized by X‑ray diffraction and the surface morphology by light optical microscopy. It was found that the nanocrystalline γ-phase structure of the sputtered alumina coatings is thermally stable at least up to 1000°C Above this temperature the γ-to-α transformation occurs and is affected by the heating rate, the annealing temperature, the annealing time and the thickness of the coating. The γ-to-α transformation is accompanied by the cracking of the coating and by the formation of a metastable θ-Al2O3 phase. Its existence is, however, limited only to very narrow temperature and time range. Furthermore, kinetic data will be presented and the effect of additional elements on thermal stability of the metastable γ‑phase structure will be discussed.

4:50 PM B1-2-11 Effect of Seed Layer Composition on the Structure of Arc-Evaporated High Al2O3 Containing (Al,Cr)2O3 Hard Coatings
Markus Pohler, Robert Franz (Montanuniversität Leoben, Austria); Jürgen Ramm (OC Oerlikon Balzers AG, Liechtenstein); Conrad Polzer (PLANSEE Composite Materials GmbH, Germany); Christian Mitterer (Montanuniversität Leoben, Austria)
The nucleation of Al2O3 coatings in the corundum type crystal structure is strongly promoted by the addition of Cr2O3. Due to a rare combination of properties such as complete solid solution of Cr2O3 in Al2O3, low formation temperature, high melting point and good hardness, Cr2O3 is an ideal candidate to overcome the needs of high formation temperatures and to avoid the unfavorable polymorphism of Al2O3. Nevertheless, the cathodic arc deposition of crystalline corundum type (Al,Cr)2O3 coatings reaches its limit for Al2O3 concentrations higher than 70 mol-%. The use of thin seed layers seems to be a promising tool to control the growth of coatings having the corundum structure even at higher Al2O3 contents. The aim of this work was to investigate the influence of different (AlxCr1‑x)2O3 seed layers with x = 0.25, 0.5 and 0.6 on the morphology, microstructure and properties of corundum type (Al0.7Cr0.3)2O3 and (Al0.85Cr0.15)2O3 coatings. All coatings were synthesized in an industrial scale cathodic arc evaporation system using powder metallurgically produced AlCr compound targets with different Al/Cr ratio. The coatings were deposited in pure oxygen at 550°C. A dense and fine grained structure was obtained for all coatings, as observed by scanning electron microscopy. Investigations of the coating microstructure by glancing angle X-ray diffraction displayed a significantly increased crystallinity of the top-layer, e.g., (Al0.7Cr0.3)2O3 on the (Al0.25Cr0.75)2O3 seed layer compared to the coatings without seed layer. Biaxial stress measurements revealed a reduction of residual tensile stress from 200 to 65 MPa with decreasing Al2O3 content in the seed layer from 60 to 25 mol-%. Transmission electron microscopy shows pronounced columnar crystal growth of the top-layer in corundum type structure already in the very early growth stages. The experimental results however, showed that a minimal seed layer thickness seems to be necessary to stimulate columnar growth of the top-layer.
5:10 PM B1-2-12 Face-Centered Cubic (Al1-xCrx)2O3 Thin Films: Deposition, Characterization, and Heat Treatment Studies
Ali Khatibi, Justinas Palisaitis, Per Persson, Jens Jensen, Jens Birch, Per Eklund, Lars Hultman (Linköping University, Sweden)

Face centered cubic (Al1-xCrx)2O3 solid solution films, with x in the range 0.60<x<0.70, have been deposited using dual reactive RF magnetron sputtering from Al and Cr targets in mixed Ar/O2 discharge at a substrate temperature of 500°C. The films have a strong <100> preferred orientation. The unit cell parameter is 4.04 Å determined by x-ray diffraction and high resolution transmission electron microscopy techniques. The (Al1-xCrx)2O3 films are suggested to have a non-stoichiometric NaCl structure with 33% vacancy occupancy on Al/Cr sites. Nanoindentation shows that the films exhibit hardness values up to 26 Gpa and reduced modulus of 220-235 Gpa. In the present work, in-situ annealing studies were performed on as-deposited samples for a series of temperatures up to 1100°C and annealing time of 8 h. The results show that fcc structure remains intact up to 950°C. A gradual phase transformation from fcc to corundum at 1000°C is observed, where annealing for 1-3 h yields a partial transformation and annealing for > 4 h results in complete transformation to alpha-(Al1-xCrx)2O3. There is no indication of any phase separation into alpha-Cr2O3 and alpha-Al2O3.

5:30 PM B1-2-13 Synthesis of Free Standing Al-Cu Intermetallics by Cathodic Arc Plasma Treatment
Erdem Arpat, Mustafa Urgen (Istanbul Technical University, Turkey)
In this study; a new approach based on cathodic arc plasma treatment, introduced by Urgen and Çorlu1,2, was utilized to produce free standing bulk alloys/ intermetallics in a cathodic arc PVD environment. Al-Cu binary couple was selected as an example, in which Al cathode as alloying material and Cu foil as substrate are used. Alloying was done by using cathodic arc plasma of Al and different deposition/ bombarding bias voltages which were applied to Cu foil substrate. Two different bias voltages were selected obtain adequate temperature that will allow maximum diffusion but securing the foil substrate from melting, (850°C nominal for the Cu-rich side of the Al-Cu phase diagram). Al-rich droplets and metastable phases at the surfaces within as processed materials were detected by standard characterization techniques. A second step of annealing at 700°C was also carried out to overcome heterogeneity. 25 μm thick Cu-rich γ-Al4Cu9, δ-Al2Cu3, ζ-Al3Cu4 intermetallics were produced. Mechanical, optical and conductance of these intermetallics were also determined.
Time Period TuA Sessions | Abstract Timeline | Topic B Sessions | Time Periods | Topics | ICMCTF2011 Schedule