Nanocrystalline silicon TFT process using silane diluted in argon–hydrogen mixtures

We have investigated the effect of Ar dilution on the deposition process of intrinsic nc-Si:H (hydrogenated nanocrystalline silicon) thin films used as active layers of top-gate TFTs, in order to improve the TFTs performances. The nc-Si:H films were deposited by plasma enhanced chemical vapor deposition (PECVD) at low temperature (165 °C) and the related TFTs were fabricated with a maximum process temperature of 200 °C. During the nc-Si:H films deposition, the SiH₄ fraction and the total flow of the diluting gases Ar + H₂ mixture was kept constant, H₂ being substituted by Ar. We have pointed out the active role played by the metastable states of excited Ar atoms in both the dissociation of SiH₄ and H₂ by quenching reactions in the plasma. The role of the atomic hydrogen during the film deposition seems to be promoted by the addition of argon into the discharge, leading to an increase of the deposition rate by a factor of about three and an enhancement of the crystalline quality of the nc-Si:H films. This effect is maximized when the Ar fraction in the Ar + H₂ gases mixture reaches 50%. The evolution with Ar addition of the carriers mobility of the related TFTs is closely connected to the evolution of the crystalline fraction of the intrinsic nc-Si:H film. Mobilities values as high as 8 cm² V^?1 s^?1 are obtained at the Ar fraction of 50%. For higher Ar fractions, the fall of the mobility comes with a degradation of the I_D–V_G transfer characteristics of the processed TFTs due to a degradation of the nc-Si:H films quality. OES measurements show that the evolution of the H_α intensity is closely connected to the evolution of the deposition rate, intrinsic films crystalline fraction and TFTs mobility, providing an interesting tool to monitor the TFTs performances.     

Characterization of a-B5C:H prepared by PECVD of orthocarborane: Results of preliminary FTIR and nuclear reaction analysis studies

The electronic properties of a-Si:H vary with hydrogen passivation of dangling bond defects. It appears this effect is also operative in semiconducting amorphous hydrogenated boron carbide (a-B₅C:H). Therefore, the ability to quantify the amount of hydrogen will be key to development of the materials science of a-B₅C:H. The results of an initial investigation probing the ability to quickly correlate hydrogen concentration in a-B₅C:H films with infrared spectroscopy are reported. a-B₅C:H thin films were growth on Si (1 1 1) substrates by plasma-enhanced chemical vapor deposition (PECVD) using sublimed orthocarborane and argon as the precursor gas. Nuclear reaction analysis (NRA) was performed to quantify the atomic concentration of H in the a-B₅C:H films. While the observed vibronic structure does not show stretches due to terminal C–H or bridging B–H–B, analysis of the terminal B–H stretch at ～2570 cm^?1 gives a proportionality constant of A = 2 × 10²² cm^?2. We conclude that the methods previously developed for correlating H concentration to infrared data in a-Si:H are similarly viable for a-B₅C:H films.     

Effect of illumination on hydrogenated amorphous silicon thin films doped with chalcogens

Hydrogenated amorphous silicon thin films doped with chalcogens (Se or S) were prepared by the decomposition of silane (SiH₄) and H₂Se/H₂S gas mixtures in an RF plasma glow discharge on 7059 corning glass at a substrate temperature 230 °C. The illumination measurements were performed on these samples as a function of doping concentration, temperature and optical density. The activation energy varied with doping concentration and is higher in Se-doped than S-doped a-Si:H thin films due to a low defect density. From intensity versus photoconductivity data, it is observed that the addition of Se and S changes the recombination mechanism from monomolecular at low doping concentration films to bimolecular at higher doping levels. The photosensitivity (σ_ph/σ_d) of a-Si, Se:H thin films decreases as the gas ratio H₂Se/SiH₄ increased from 10^?4 to 10^?1, while the photosensitivity of a-Si, S:H thin films increases as the gas ratio H₂S/SiH₄ increased from 6.8 × 10^?7 to 1.0×10^?4.     

New insights in microcrystalline silicon deposition with expanding thermal plasma chemical vapor deposition

We report on further insights in the microcrystalline silicon (μc-Si:H) deposition using expanding thermal plasma chemical vapor deposition. We have shown before that the refractive index at 2 eV of μc-Si:H layers increased if the silane (SiH₄) was injected close to the substrate, while the deposition rate remained the same. We argued that at high injection-ring position, the SiH₄ travels a long way to the substrate and therefore has a long interaction time with the plasma, in particular atomic hydrogen. In this way, the SiH₄ injection position influences the number of hydrogen atoms stripped from the SiH₄ as well as the consumption of atomic hydrogen. In this paper, we present an analysis of the growth flux of depositing particles as function of the radical production rate. The data suggest that there is no dependence on the SiH₄ injection position, implying that the mix of depositing radicals is not changed. However, the data also show the microcrystalline-to-amorphous transition shifts to higher SiH₄ flows for lower injection positions. We therefore now think that it is not the interaction time between the SiH₄ and the arc plasma determining the material properties, but the interaction of excess atomic hydrogen with the μc-Si:H growth surface.     

Toward the fast deposition of highly crystallized microcrystalline silicon films with low defect density for Si thin-film solar cells

In this study, employing a high-density, low-temperature SiH₄–H₂ mixture microwave plasma, we investigate the influence of source gas supply configuration on deposition rate and structural properties of microcrystalline silicon (μc-Si) films, and demonstrate the plasma parameters for fast deposition of highly crystallized μc-Si films with low defect density. A fast deposition rate of 65 Å/s has been achieved for a SiH₄ concentration of 67% diluted in H₂ with a high Raman crystallinity of X_c > 65% and a low defect density of (1–2) × 10¹⁶ cm⁻³ by adjusting source gas supply configuration and plasma conditions. A sufficient supply of deposition precursors, such as SiH₃, as well as atomic hydrogen H on film growing surface is effective for the high-rate synthesis of highly crystallized μc-Si films, for the reduction in defect density, and for the improvement in film homogeneity and compactability. A preliminary result of p–i–n structure μc-Si thin-film solar cells using the resulting μc-Si films as an intrinsic absorption layer is presented.     

Enhanced spectral response by silicon nitride index matching layer in amorphous silicon thin-film solar cells

We employed the low temperature hydrogenated amorphous silicon nitride (a-SiN_x:H) prepared by plasma-enhanced chemical vapor deposition as a refractive index (n) matching layers in a silicon-based thin-film solar cell between glass (n = 1.5) and the transparent conducting oxide (n = 2). By varying the stoichiometry, refractive index and thickness of the a-SiN_x:H layers, we enhanced the spectral response and efficiency of the hydrogenated amorphous silicon thin-film solar cells. The refractive index of a-SiN_x:H was reduced from 2.32 to 1.78. Optimizing the a-SiN_x:H thickness to 80 nm increased the J_SC from 8.3 to 9.8 mA/cm² and the corresponding cell efficiency increased from 4.5 to 5.3%, as compared to the cell without the a-SiN_x:H index-matching layer on planar substrate. The a-SiN_x:H layers with graded refractive indices were effective for enhancing the cell performance.     

Large grain μc-Si:H films deposited at low temperature: Growth process and electronic properties

We have studied structural and electronic properties of μc-Si:H films deposited from SiH₄ + H₂ and SiH₄ + H₂ + Ar gas mixtures. The use of Ar containing gas mixtures for depositions allows us to increase deposition rate by a factor of two and to obtain films with an important fraction of large grains in comparison with SiH₄ + H₂ gas mixtures. Electronic properties of fully crystallized films become more intrinsic with the increase of large grain fraction. Deposition of highly p- and n-doped μc-Si:H layers from the dopant/SiH₄ + H₂ gas mixture at a temperature of 175 °C is possible without any remarkable changes in crystallinity in comparison with undoped films deposited with the same discharge conditions.     

Deposition of phosphorus doped a-Si:H and μc-Si:H using a novel linear RF source

A roll-to-roll PECVD system for thin film silicon solar cells on steel foil has been developed by ECN in collaboration with Roth and Rau AG. It combines MW–PECVD for fast deposition of intrinsic Si and novel linear RF sources, which apply very mild deposition conditions, for the growth of doped Si layers. The RF and MW sources can be easily scaled up to deposition widths of up to 150 cm. Here, we report on n-type doping, achieved by RF–PECVD from a H₂/SiH₄/PH₃ mixture in the reaction chamber. The best n-type a-Si:H layers showed E_act = 0.27 eV and σ_d = 2.7 × 10^?3 S/cm. Also thin layers down to 20 nm were of device quality and were deposited at a rate of 0.4 Å/s. Furthermore, n-type μc-Si:H layers with thicknesses of 150 nm, with E_act = 0.034 eV and σ_d = 2 S/cm were grown. Good quality n-type μc-Si:H layers can be made for layer thicknesses down to 50 nm at a rate of 0.15 Å/s. To conclude, the novel RF source is well-suited for the growth of n-doped a-Si:H and μc-Si:H layers for roll-to-roll solar cell production.     

Photoelectric features of vacuum-deposited a-Si:H/Alq3 blends

Using three electrode vacuum system for glow discharge of 5% SiH₄ + 95% Ar gas mixture together with thermal evaporation of phosphorus or boric aced, the n- and p-type a-Si:H layers have been deposited. By co-evaporation of phosphorus or boric aced the conductivity of a-Si:H layers was changed in 10^?11–10^?3 Ω^?1 cm^?1 or 10^?11 –10^?8 Ω^?1 cm^?1 range, respectively. Blends of a-Si:H and tris-(8-hydroxyquinoline) aluminum (Alq₃) have been vacuum-deposited by simultaneous glow discharge of 5% SiH₄ + 95 % Ar gas mixture and thermal co-evaporation of Alq₃. Photoluminescence spectrum of a-Si:H/Alq₃ blend coincident with one of Alq₃ was observed at room temperature.     

Effect of hot-wire passivation on the properties of hydrogenated microcrystalline silicon films to reduce post-deposition oxidation

Hydrogenated microcrystalline silicon (μc-Si:H) films have a large number of grain boundaries that oxidize after deposition, leading to deterioration of device performance. In this study, post-treatment of μc-Si:H thin films was carried out with methane-related radicals generated by a hot wire. The effect of the hot-wire passivation on the properties of the μc-Si:H thin films was investigated using Fourier-transform infrared (FT-IR) transmission spectroscopy. Through post-treatment, hydrogen on the silicon-crystallite surface was substituted with hydrocarbon. Further, an increase in filament temperature (T_ft) was found to enhance passivation. For films treated at T_ft above 1700 °C, post-oxidation and nitridation hardly occurred, whereas films treated at T_ft below 1400 °C were oxidized and nitrided even after post-treatment.     

Self-assembling of supramolecular erbium–oxygen clusters in magnetron plasma,and the optimization of erbium luminescence in a-SiOx:H〈Er, O〉 films

Films of erbium-doped amorphous hydrogenated silicon a-SiO_x:H〈Er, O〉 were fabricated by dc-magnetron sputtering at different concentrations of oxygen in the magnetron plasma and different areas of erbium metallic target. It was demonstrated that the increase of oxygen concentration in the plasma gaseous phase above ∼5 mol% leads to a sharp rise in the amount of oxygen bound to erbium in the a-SiO_x:H〈Er, O〉 films. Simultaneously, a smooth increase in the concentration of oxygen bound to matrix-forming elements (silicon, hydrogen) is observed. The increase of the area of erbium target, corresponding to the rise of concentration of erbium ions in the plasma, also favors the binding of erbium with oxygen. However, the content of erbium in the a-SiO_x:H〈Er, O〉 film (in atomic percents) significantly drops with intense binding of erbium with oxygen. These facts point to the formation of erbium–oxygen clusters, with a large number of oxygen atoms, which are probably formed in the magnetron plasma but are deposited as a separate species on the substrate in the reaction chamber. The intensity of erbium photoluminescence rises significantly in the region of formation of these large erbium–oxygen clusters. A ‘phase-transition’ model is formulated, describing the properties of a-SiO_x:H〈Er, O〉 films, based on the assumption of the formation of large erbium–oxygen clusters in the magnetron plasma. The size and composition of these clusters are determined. The model is semi-quantitatively consistent with all the experimental findings.     

Influence of hydrogen on the thermomechanical properties of a-CNx:H and a-CNx films deposited by glow discharge and ion beam assisted deposition

The coefficient of thermal expansion (CTE), Young’s modulus, Poisson’s ratio, stress and hardness of a-CN_x and a-CN_x:H were investigated as a function of nitrogen concentration. Hydrogenated films were prepared by glow discharge, GD, and unhydrogenated films were prepared by ion beam assisted deposition, IBAD. Using nanohardness measurements and the thermally induced bending technique, it was possible to extract separately, Young’s modulus and Poisson’s ratio. A strong influence of hydrogen, in a-CN_x:H films, was observed on the CTE, which reaches about ∼9 × 10⁻⁶ C⁻¹, close to that of graphite (∼8 × 10⁻⁶ C⁻¹) for nitrogen concentration as low as 5 at.%. On the other hand, the CTE of unhydrogenated films increases with nitrogen concentration at a much lower rate, reaching 5.5 × 10⁻⁶ C⁻¹ for 33 at.% nitrogen.     

Local bonding of hydrogen in a-Si:H,a-Ge:H and a-Si,Ge:H alloy films

This paper reviews the local bonding of hydrogen (and deuterium) in a-Si:H(D), a-Ge:H(D) and a-Si, Ge:H(D) alloy films. We specify the types of atomic environments that have been identified through vibrational spectroscopy, primarily infrared (IR) absorption. We emphasize local modes and discuss the atomic motions that are responsible for the various spectral features. We discuss correlations between the occurrence of specific local bonding groups, e.g., polysilane and polygermane configurations, and the deposition techniques and parameters, including the substrate temperature (T_s), the gas mixtures and the RF power into a glow discharge, etc. We include a discussion of the theoretical approaches that have been used to treat vibrational modes in these materials. We emphasize the approximations that are valid because of the relatively light mass of the hydrogen and deuterium atoms compared with those of the silicon and germanium atoms. Finally we highlight the effects of neighboring alloy or impurity atoms on the frequencies of hydrogen vibrations in a-Si:H, and point out the differences between oxygen atom incorporation in a-Si and a-Ge alloys.     

Thermodynamic analysis of gas phase chemistry in hot wire chemical vapor deposition of a-Si:H and μc-Si:H

Gas phase reactions amongst filament-generated radicals play a crucial role in growth and properties of films deposited by hot wire chemical vapor deposition (HWCVD) technology. Gas phase species of interest are SiH₄, H₂, Si, H, SiH₃, SiH₂ and SiH. Partial pressures of these species for different sets of deposition conditions have been determined from the standard Gibbs free energy data. Equilibrium concentrations of the film forming precursors have been determined. The effect of the various process parameters on the equilibrium concentration of the precursors has been studied. H, Si and SiH are found to be the dominant species in gas phase above a filament temperature of 2300 K. However SiH₃ and SiH₂ concentration peaks are between 1900 and 2300 K, of the filament temperature.     

Transition from amorphous semiconductor to amorphous insulator in hydrogenated carbon–germanium films investigated by IR spectroscopy

Thin a-Ge_XC_1?X:H plasma polymerized films, depending on deposition conditions, can be produced in two very different structures, namely amorphous semiconductor and amorphous insulator. The transition from amorphous insulator to amorphous semiconductor is related to the formation of germanium nanoclusters due to ions bombarding the surface of the growing material. This paper concentrates on investigations of the transition by means of IR spectroscopy. To this end a quantitative analysis of IR spectra obtained for thin films deposited on silicon substrate has been described and used for estimation of hydrogen atom concentration and bonding in the investigated material. It was found that the probability that a given H atom is bonded to a germanium or to a carbon atom is almost the same. This conclusion is true both for a-S and a-I films. The average concentration of hydrogen in the investigated material was found to be about 2.4–3.4 × 10²² cm^?2 which means that there are two times more atoms of the carbon family than hydrogen atoms in the film structure.     

The interpretation of the electric and optical properties of a-Si:H films produced by rf glow discharge through dark conductivity,photoconductivity and pulse controlled capacitance-voltage measurements

This paper deals with the interpretation of transport properties of amorphous silicon hydrogenated films (a-Si:H) through dark conductivity, photoconductivity and pulse controlled capacitance-voltage measurements. a-Si:H films were produced by rf glow discharge coupled either inductively or capacitively to a 3% SiH₄/Ar mixture at different crossed electromagnetic static fields. The data concerned with the dark activation energy, photoactivation energy, variation of the density of localized states and photosensitivity, (σ_ph/σ_d)_25°C, of a-Si:H films can account for their optoelectronic properties which are strongly dependent on the deposition parameters. We also observed that crossed electromagnetic static fields applied during film formation influences hydrogen incorporation in a different manner than previously proposed.     

Synthesis and characterization of bulk amorphous Zr65Cu18Ni9Al8 and [Zr0.65Cu0.18Ni0.09Al0.08]98Er2 alloys

Bulk metallic glasses (BMGs), especially Zr-based BMGs, have attracted lot of attention of materials scientists because of their very attractive physical, thermal and mechanical properties and a few unique applications. In the present study, Zr₆₅Cu₁₈Ni₉Al₈ alloy was designed according to the criterion of conduction electron/atom (e/a ratio) ∼1.395 and average atomic size of alloy (R_a) ∼0.1498 nm. Addition of 2 at.% Er was carried out in the base alloy to investigate its effect on thermal and mechanical properties. Characterization of alloys was performed using the techniques of XRD, DSC, and SEM/EDS. Mechanical properties like Vicker’s microhardness, nanohardness, elastic modulus, density and fracture strength were measured. Average shear angle was found to be ∼35 ± 1° for base alloy and about 31 ± 1° for alloy containing 2 at.% Er. Wide supercooled liquid regions of 129 K and 119 K were found for the base alloy and the alloy containing 2 at.% Er.     

Influence of the amorphous/crystalline silicon heterostructure properties on planar conductance measurements

We report a quasi-analytical calculation describing the heterojunction between hydrogenated amorphous silicon (a-Si:H) and crystalline silicon (c-Si) at equilibrium. It has been developed and used to determine the carrier sheet density in the strongly inverted layer at the a-Si:H/ c-Si interface. The model assumes an exponential band tail for the defect distribution in a-Si:H. The effects of the different parameters involved in the calculation are investigated in detail, such as the Fermi level position in a-Si:H, the density of states and the band offsets. The calculation was used to interpret temperature dependent planar conductance measurements carried out on (n) a-Si:H/ (p) c-Si and (p) a-Si:H/(n) c-Si structures, which allowed us to confirm a previous evaluation of the conduction band offset, ?E_C = 0.18 ± 0.05 eV, and to evaluate the valence band offset: ?E_V = 0.36 ± 0.05 eV at the a-Si:H/ c-Si heterojunction. The results are placed in the frame of recent publications.     

Heat treatment of amorphous silicon p-i-n solar cells with high-pressure H2O vapor

We report improvement in characteristics of hydrogenated amorphous silicon (a-Si:H ) p-i-n structured solar cells by high-pressure H₂O vapor heat treatment. a-Si:H p-i-n solar cells were formed on glass substrates coated with textured SnO₂ layer. P-, i-, and n-type a-Si:H layers were subsequently formed by plasma enhanced chemical vapor deposition. Finally an indium-tin-oxide layer was coated on the n-type a-Si:H surface. Heat treatment at 210 °C with 2 × 10⁵ Pa H₂O vapor for 1 h was applied to the a-Si:H p-i-n solar cells. Electrical characteristics were measured when samples were kept in dark and illuminated with light of AM 1.5 at 100 mW/cm². The heat treatment with H₂O vapor increased fill factor (FF) and the conversion efficiency from 0.54 and 7.7% (initial) to 0.57 and 8.4%, respectively. Marked improvement in solar cell characteristics was also observed in the case of a poor a-Si:H p-i-n solar cell. FF and the conversion efficiency were increased from 0.29 and 3.2% (initial) to 0.56 and 7.7%, respectively.     

Structure and optical properties of light-emitting Si films fabricated by neutral cluster deposition and subsequent high-temperature annealing

As a new development of our previous study on the production of light-emitting amorphous Si (a-Si) films by the neutral cluster deposition (NCD) method, we have fabricated light-emitting Si films with improved emission intensity by the combined methods of NCD and subsequent high-temperature annealing. The structure of these films is best characterized by Si nanocrystals, surrounded by an interfacial a-SiO_x (x < 2) layer, embedded in an a-SiO₂ film. These improved Si films were observed by atomic force microscopy and high-resolution transmission electron microscopy, and analyzed by means of X-ray diffraction, X-ray photoelectron spectroscopy, photoluminescence (PL) and Fourier transform infrared-attenuated total reflection measurements. The PL curves of the annealed samples exhibit peaks around 600 nm, at almost the same position as the unannealed samples. Their PL intensities, however, have increased to approximately five times those of the unannealed samples. The source of the luminescence is most likely due to electron-hole recombination in the a-SiO₂/Si interfacial a-SiO_x layer.