Papers by Author: Noboru Ohtani

Abstract: Silicon carbide (SiC) wafers are essential for next-generation power devices, however conventional dicing methods often induce cracks and Basal Plane Dislocations (BPDs), reducing device reliability. This study demonstrates BPD-free dicing of epitaxial SiC wafers using Water jet Guided Laser (WGL) processing. Full-thickness cutting was performed on 350 μm-thickness wafers with a 10 μm-thickness epitaxial layer using a YAG laser (532 nm wavelength, 200 ns pulse width, 10 kHz repetition rate, 30–80 W output) on an LB300 system. BPD evaluation was carried out by X-ray topography (XRT) with the-1-128 reflection before and after cutting. The results showed no generation or propagation of new BPDs, and pre-existing BPDs did not glide, confirming that WGL processing enables BPD-free machining. These results are attributed to the ablation-based nature of WGL with water assistance, which avoids mechanical stress on epitaxial SiC wafers.

Abstract: Low-process damage dicing technologies are required to improve the reliability of silicon carbide (SiC) devices. Existing methods, such as ultrasonic diamond blade dicing, dry laser dicing, and stealth dicing, introduce mechanical or thermal stresses that lead to cracks and dislocations, including basal plane dislocations (BPDs), which degrade device quality. In this study, we assess the crystalline defects induced by water jet guided laser (WGL) processing on a SiC wafer using X-ray topography (XRT) and investigate the underlying processing mechanisms through Energy Dispersive X-ray Spectroscopy (EDX). The asymmetric contrast observed along the processed grooves in the XRT images was due to the X-ray irradiation direction, and no significant BPD formation was observed. The EDX results showed that the processed surface was oxidized by laser ablation. Thus, WGL processing can provide damage-free dicing of SiC wafers with minimal mechanical stress and defects.

Abstract: A damage-free SiC wafer dicing method has been strongly required for practical applications of power devices. In this research, we propose water jet guided laser processing as a novel dicing method. Water jet guided laser processing, which uses a high-pressure fine water jet as waveguide, could generate no cracks or dislocations in crystal. In this paper, water jet guided laser grooving quality was evaluated to demonstrate there should be no chippings and basal plane dislocations. Scanning electron microscopic and X-ray topography observations were conducted. The results indicated the superiority of water jet guided laser dicing to a conventional dicing method.

Abstract: The defect structure at the growth front of 4H-SiC boules grown using the physical vapor transport (PVT) method has been investigated using high resolution x-ray diffraction and x-ray topography. The crystal parameters such as the c-lattice constant exhibited characteristic variations across the growth front, which appeared to be caused by variation in surface morphology of the as-grown surface of the boules rather than the defect structure underneath the surface. X-ray topography also revealed that basal plane dislocations are hardly nucleated at the growth front during PVT growth of 4H-SiC crystals.

Abstract: We investigated the run-to-run fluctuation in growth conditions of physical vapor transport growth of 4H-SiC boules through observations of surface morphology on the (000-1) facet of the boules. The boules, which were grown under the same macroscopic growth conditions, exhibited slightly different surface morphologies. This indicates that some microscopic growth parameters that influence the surface morphology fluctuate between growth runs. We have considered the C/Si ratio of the vapor sublimed from the source material as a major parameter and discussed the associated variations in the physical and surface properties of the grown crystals.

Abstract: The annealing behavior of electrical resistivities perpendicular and parallel to the basal plane of heavily nitrogen-doped 4H-SiC crystals was investigated. The temperature dependencies of the resistivities exhibited characteristic behaviors after multiple rounds of high-temperature annealing (1100°C, 30 min). High-temperature annealing induced stacking fault formation to various extents in heavily nitrogen-doped 4H-SiC crystals. Based on these results, we discuss the cause and mechanism of the observed annealing-induced changes in electrical resistivities of the crystals.

Abstract: The strain fields in a 4H-SiC homo-epitaxial layer deposited on a nitrogen-doped 4H-SiC substrate were studied using Raman scattering microscopy. The cross-sectional (1-100) and (11-20) surfaces of the epitaxial substrate were examined through the peak shifts of several Raman-active phonon modes for 4H-SiC, and tensile strain was found along the direction of 4° off the c-axis at the epilayer/substrate interface. The effect of the facet trace in the substrate, which has a higher nitrogen concentration than the other parts of the substrate, was also studied. The tensile strain at the epilayer/substrate interface was found to be hardly enhanced for the epilayer deposited on the facet trace.

Abstract: Step bunching on a vicinal 4H-SiC (0001) epitaxial layer surface was investigated using low-voltage electron scanning microscopy (LVSEM) and electron channeling contrast (ECC) imaging. LVSEM observations revealed that the step bunching resulted in the formation of atomically flat wide (~250 nm) terraces on the surface, and the terraces tended to form in pairs. The two terraces in paired terraces often showed the same electron channeling contrast as each other, and the contrast of the two terraces, either bright or dark, appeared to be determined by the orthogonal misorientation of substrates. On the basis of these results, the formation mechanism of the step-bunched structure on a vicinal 4H-SiC (0001) surface is discussed.

Abstract: The stacking fault formation during physical vapor transport growth of heavily nitrogen-doped (mid-10¹⁹ cm⁻³) 4H-SiC crystals was investigated. Low-voltage scanning electron microscopy (LVSEM) observations detected the stacking fault formation on the (000-1) facet of heavily nitrogen-doped 4H-SiC crystals. Stacking faults showed characteristic morphologies, and atomic force microscopy (AFM) studies revealed that these morphologies of stacking faults stemmed from the interaction between surface steps and stacking faults. Based on these results, the stacking fault formation mechanism in heavily nitrogen-doped 4H-SiC crystals is discussed.

Abstract: We have established the grazing-incidence x-ray diffraction (GIXD) method under ultra- high temperature for in-situ crystal growth observation. For this purpose, we have developed the compact furnace which can be mounted on a goniometer used for the GIXD experiment. Using the custom-designed furnace, we have succeeded in controlling very high temperature around 1800°C. Subsequently, we have proved the performance of the furnace through the measurement of the tem- perature dependence of a-lattice constant of 4H-SiC in the range from room temperature to 1500 °C.