Papers by Author: Mike F. MacMillan

Abstract: Effective recombination lifetimes of 4H-SiC PiN epitaxy wafers are measured by -PCD (microwave photoconductive decay) system at wafer level. Lifetimes measured in presence and absence of the p+ layer show lower lifetime values with p+ layer present. This is attributed to high recombination rate at p+/n- interface. Lifetimes at various buffer thicknesses show lower values at the buffer layer of about 50 m due to high interface recombination rate resulting from rougher surface of the buffer layer. Lifetimes of PiN wafers from interrupted and continuous p+/n- growth are very comparable.

Abstract: Grazing-incidence synchrotron topography studies of micropipes (MPs) and closed-core threading screw dislocations (TSDs) have been carried out and the results compared with ray-tracing simulations. Simulations indicate that both MPs and TSDs appear as roughly elliptically shaped white features which are canted to one side or the other of the g-vector depending on the dislocation sense and which have asymmetric perimeters of dark contrast which are greatly enhanced on the side towards which the feature is canted (again depending on the dislocation sense). For MPs, observations are generally consistent with this although the cant of the features is more obviously discerned than the asymmetry in the perimeter contrast. Sense assignment for MPs has been validated using back-reflection reticulography. For TSDs, observation are again generally consistent with the simulations although the smaller feature size and the variability in the line direction of the TSDs make the asymmetry of perimeter contrast a more obvious and reliable way to determine the dislocation sense than the sense of cant. TSD dislocation senses so obtained were validated using back-reflection images of same-sign and opposite-sign pairs.

Abstract: Thick (> 25 µm) 4H n+ epitaxial layer growth was performed on 4H n+ substrates utilizing chlorine containing etch chemistries in a hot wall CVD system. Optimization of the n+ epitaxial layer growth was achieved by varying C/Si ratio and N2 flow. Desired epitaxial layers have doping levels > 5x1018 cm-3, epitaxial surface roughness <10 nm on a 20x20 µm area and overall micropipe density reduction. To confirm the conversion of micropipes into closed core screw dislocations, microscopic examination of the epitaxial and wafer surfaces was carried out after KOH etching. Grazing incidence x-ray topography (XRT) as well as cross sectional XRT and microscopy were also performed. The cross sectional evaluation showed that the dissociation of the micropipes occurs very close to the epitaxy/wafer interface.

Abstract: Excess carrier lifetimes in 4H SiC epitaxial wafers were characterized by microwave photoconductive decay (o/PCD). The measured decay compromised of surface and bulk recombination curves have fast and slow components. Measured lifetimes are not changed with various surface passivation techniques. High resolution lifetime maps show good correlation with stress birefringence images and lower lifetime around extended material defects like grainboundaries, defect clusters, edge defects and polytype switching bands. Chlorosilane based CVD epiwafers show higher bulk lifetime values than standard silane based CVD materials due to less bulk lifetime defect density.

Abstract: A SiC epitaxy process based on chlorosilane/propane chemistry has been successfully transferred from a single-wafer R&D system to a multi-wafer CVD reactor. The optimized process results in very smooth epi surface (RMS~0.24nm) and minimum surface pits (less than 0.5/cm2). Both n-type and p-type doping in a wide range are demonstrated using nitrogen and aluminum, respectively. The high performance benchmarks for thickness uniformity (intra-wafer variation <1% and inter-wafer variation <1%) and doping uniformity (intra-wafer variation <6% and inter-wafer variation <3%) are achieved on 5 x 3-inch wafers. The carrier lifetime in these epilayers measured by μ-PCD is over 5 μs, the longest value reported so far for SiC epitaxial wafers.

Abstract: Gas phase etching of 4H SiC n+ substrates was performed utilizing chlorine containing etch chemistries in a hot wall CVD system. Carbon and silicon vapor were added to explore selective etching reactions on the wafer surface. The impact of the etch on the bare wafer surface as a function of temperature and etch chemistry is investigated. Selection of the etch chemistry and temperature are critical to ensure a smooth etched surface on which to begin epitaxial deposition. Etching also influences defect propagation from the substrate into the epitaxial layer. The results show etch chemistry reactions will influence the conversion of micropipes in the epi buffer layer.

Abstract: Epitaxial growth of SiC films was performed on 4H SiC n+ substrates utilizing a chlorosilane/propane chemistry in both single wafer and batch CVD systems. Variations of the chlorosilane flow under fixed conditions of gas composition, temperature and pressure resulted in growth rates between 4 to 20 μm/hr. Fixing the chlorosilane flow rate to achieve a growth rate of approximately 4 μm/hr, the effects of temperature, pressure and gas composition on background dopant incorporation, epitaxial layer uniformity and epitaxial defect generation were investigated. Intentional n and p-type doping has been demonstrated over the carrier range 1×1018-1×1020/cm3. This paper presents the first reported of use of chlorosilane precursors to grow high quality undoped, n and p doped SiC epilayers.