Stephan G. Mueller

Stacking faults created by the combined deflection of threading dislocations of Burgers vector c and c+a during the physical vapor transport growth of 4H–SiC

Observations have been made, using synchrotron white beam x-ray topography, of stacking faults in 4H–SiC with fault vectors of kind 1/6⟨202¯3⟩. A mechanism has been postulated for their formation which involves overgrowth by a macrostep of the surface outcrop of a c-axis threading screw dislocation, with two c/2-height surface spiral steps, which has several threading dislocations of Burgers vector c+a, with c-height spiral steps, which protrude onto the terrace in between the c/2-risers. Such overgrowth processes deflect the threading dislocations onto the basal plane, enabling them to exit the crystal and thereby providing a mechanism to lower their densities.

The Nucleation and Propagation of Threading Dislocations with c-Component of Burgers Vector in PVT-Grown 4H-SiC

Studies of threading dislocations with Burgers vector of c+a have been carried out using synchrotron white beam X-ray topography. The nucleation and propagation of pairs of opposite sign threading c+a dislocations is observed. Overgrowth of inclusions by growth steps leads to lattice closure failure and the stresses associated with this can be relaxed by the nucleation of opposite sign pairs of dislocations with Burgers vector c+a. Once these dislocations are nucleated they propagate along the c-axis growth direction, or can be deflected onto the basal plane by overgrowth of macrosteps. For the c+a dislocations, partial deflection can occasionally occur, e.g. the a-component deflects onto basal plane while the c-component continuously propagates along the growth direction. One factor controlling the details of these deflection processes is suggested to be related to the ratio between the height of the overgrowing macrostep and that of the surface spiral hillock associated with the threading growth dislocations with c-component of Burgers vector.

Basal plane dislocation multiplication via the Hopping Frank-Read source mechanism in 4H-SiC

Synchrotron white beam x-ray topography (SWBXT) observations are reported of single-ended Frank-Read sources in 4H-SiC. These result from inter-conversion between basal plane dislocations (BPDs) and threading edge dislocations (TEDs) brought about by step interactions on the growth interface resulting in a dislocation comprising several glissile BPD segments on parallel basal planes interconnected by relatively sessile TED segments. Under stress, the BPD segments become pinned by the TED segments producing single ended Frank-Read sources. Since the BPDs appear to “hop” between basal planes, this apparently dominant multiplication mechanism for BPDs in 4H-SiC is referred to as the “Hopping” Frank-Read source mechanism.

Basal Plane Dislocation Multiplication via the Hopping Frank-Read Source Mechanism and Observations of Prismatic Glide in 4H-SiC

In this paper, we report on the synchrotron white beam topographic (SWBXT) observation of “hopping” Frank-Read sources in 4H-SiC. A detailed mechanism for this process is presented which involves threading edge dislocations experiencing a double deflection process involving overgrowth by a macrostep (MP) followed by impingement of that macrostep against a step moving in the opposite direction. These processes enable the single-ended Frank-Read sources created by the pinning of the deflected basal plane dislocation segments at the less mobile threading edge dislocation segments to “hop” from one slip plane to other parallel slip planes. We also report on the nucleation of 1/3< >{ } prismatic dislocation half-loops at the hollow cores of micropipes and their glide under thermal shear stress.

Measurement of Critical Thickness for the Formation of Interfacial Dislocations and Half Loop Arrays in 4H-SiC Epilayer via X-Ray Topography

Synchrotron X-ray Beam Topography (SWBXT) and KOH etching observations are presented of interfacial dislocations (IDs) and half-loop arrays (HLAs) which can form under certain growth conditions during homoepitaxy of 4H-SiC on off-cut substrates. The HLAs and IDs are observed to form from pairs of opposite sign basal plane dislocations in the substrate which intersect the substrate surface in screw orientation. These dislocations glide in opposite direction in the epilayer once critical thickness has been exceeded. Half-loop arrays are formed at the same time as the screw-type basal plane dislocations (BPDs) side-glide inside the epilayer. From knowledge of the formation mechanism of the HLAs [, if the line of the HLA is extended to intersect the original threading dislocation line direction, then the distance between this intersection point and the ID along the line direction of the original BPD provides a measure of the critical thickness. It is also calculated that the critical thickness in this case is largely determined by the mutual attractive force between the pairs of opposite sign threading BPDs in the substrate. In addition we observed both interfacial dislocations and HLAs generated from: (a) surface sources of BPDs; (b) micropipes; (c) 3C inclusions; and (d) substrate/epilayer interface scratches.

Synchrotron X-Ray Topography Studies of the Propagation and Post-Growth Mutual Interaction of Threading Growth Dislocations with C-Component of Burgers Vector in PVT-Grown 4H-SiC

Synchrotron White Beam X-ray Topography (SWBXT) imaging of wafers cut parallel to the growth axis from 4H-SiC boules grown using Physical Vapor Transport has enabled visualization of the evolution of the defect microstructure. Here we present observations of the propagation and post-growth mutual interaction of threading growth dislocations with c-component of Burgers vector. Detailed contrast extinction studies reveal the presence of two types of such dislocations: pure c-axis screw dislocations and those with Burgers Vector n1c+n2a, where n1 is equal to 1 and n2 is equal to 1 or 2. In addition, observations of dislocation propagation show that some of the threading dislocations with c-component of Burgers adopt a curved, slightly helical morphology which can drive the dislocations from adjacent nucleation sites together enabling them to respond to the inter-dislocation forces and react. Since all of the dislocations exhibiting such helical configurations have significant screw component, and in view of the fact that such dislocations are typically not observed to glide, it is believed that such morphologies result in large part from the interaction of a non-equilibrium concentration of vacancies with the originally approximately straight dislocation cores during post-growth cooling. Such interactions can lead to complete or partial Burgers vector annihilation. Among the reactions observed are: (a) the reaction between opposite-sign threading screw dislocations with Burgers vectors c and –c wherein some segments annihilate leaving others in the form of trails of stranded loops comprising closed dislocation dipoles; (b) the reaction between threading dislocations with Burgers vectors of -c+a and c+a wherein the opposite c-components annihilate leaving behind the two a-components; (c) the similar reaction between threading dislocations with Burgers vectors of -c and c+a leaving behind the a-component.

High Quality 150 mm 4H SiC Wafers for Power Device Production

The commercial availability of high quality 150 mm 4H SiC wafers has aided in the growth of SiC power device fabrication. The progress of 150 mm 4H SiC wafer development at Dow Corning is reviewed. Defect densities compare well to those typical for 100 mm wafers, with even lower threading screw dislocation densities observed in 150 mm wafers. Resistivity data shows a comparable range from 0.012 – 0.025 ohm.cm, and excellent shape control is highlighted for wafer thicknesses of 350 μm and 500 μm.

Study of V and Y Shape Frank-Type Stacking Faults Formation in 4H-SiC Epilayer

Nomarski optical microscopic, KOH etching and synchrotron topographic studies are presented of faint needle-like surface morphological features in 4H-SiC homoepitaxial layers. Grazing incidence synchrotron white beam x-ray topographs show V shaped features which transmission topographs reveal to enclose 1/4[0001] Frank-type stacking faults. Some of these V-shaped features have a tail associated with them and are referred to as Y-shaped defects. Geometric analysis of the size and shape of the V-shaped faults indicates that they are fully contained within the epilayer and appear to be nucleated at the substrate/epilayer interface. Detailed analysis shows that the positions of the V-shaped stacking faults match with the positions of c-axis threading dislocations with Burgers vectors of c or c+a in the substrate and thus appear to result from the deflection of these dislocations onto the basal plane during epilayer growth. Similarly, the Y-shaped defects match well with the substrate surface intersections of c-axis threading dislocations with Burgers vectors of c or c+a in the substrate which were deflected onto the basal plane during substrate growth. Based on the observed morphology of these defect configurations we propose a model for their formation mechanism.

Quantitative Comparison Between Dislocation Densitiesin Offcut 4H-SiC Wafers Measured Using SynchrotronX-ray Topography and Molten KOH Etching

AbstractMolten KOH etching and x-ray topography have been well established as two of the major characterization techniques used for observing as well as analyzing the various crystallographic defects in both substrates and homoepitaxial layers of silicon carbide. Regarding assessment of dislocation density in commercial wafers, though the two techniques show good consistency in threading dislocation density analysis, significant discrepancy is found in the case of basal plane dislocations (BPDs). In this paper we compare measurements of BPD densities in 4-inch 4H-SiC commercial wafers assessed using both etching and topography methods. The ratio of the BPD density calculated from topographic images to that from etch pits is estimated to be larger than 1/sinθ, where θ is the offcut angle of the wafer. Based on the orientations of the defects in the wafers, a theoretical model is put forward to explain this disparity and two main sources of errors in assessing the BPD density using chemical etching are discussed.

Deflection of Threading Dislocations with Burgers vector c/c+a Observed in 4H-SiC PVT –Grown Substrates with Associated Stacking Faults

A review is presented of Synchrotron White Beam X-ray Topography (SWBXT) studies of stacking faults observed in PVT-Grown 4H-SiC crystals. A detailed analysis of various interesting phenomena were performed and one such observation is the deflection of threading dislocations with Burgers vector c/c+a onto the basal plane and associated stacking faults. Based on the model involving macrostep overgrowth of surface outcrops of threading dislocations, SWBXT image contrast studies of these stacking faults on different reflections and comparison with calculated phase shits for postulated fault vectors, has revealed faults to be of basically four types: (a) Frank faults; (b) Shockley faults; (c) Combined Shockley + Frank faults with fault vector s+c/2; (d) Combined Shockley + Frank faults with fault vector s+c/4.