Search

The thermoelastic stress, mechanical properties and defect content of bulk 4H n-type SiC crystals were investigated following adjustments to the PVT growth cell configuration that led to a 40% increase in growth rate. The resulting 150 mm wafers were compared with wafers produced from a control process in terms of wafer bow and warp, and dislocation density. Wafer shape was found to be comparable among the processes, indicating minimal impact on internal stress. Threading edge and threading screw dislocation densities increased and decreased, respectively, while basal plane dislocation densities were unaffected by the increase in growth rate. Loss of wafer planar stability was observed in certain cases. The elastic modulus was measured to be in the range of approximately 420-450 GPa for selected stable and unstable wafers, and was found to correspond to resistivity.

Dislocation behavior during the early stages of physical vapor transport (PVT) growth of 6-inch diameter 4H-SiC crystals has been investigated by synchrotron monochromatic beam X-ray topography (SMBXT) in conjunction with ray tracing simulations of dislocation images. Our studies reveal that most of the TSDs/TMDs are replicated into the newly grown layer while most TEDs are generated by either nucleation in pairs at the growth interface or by redirection of BPDs in the seed crystal. Most BPDs in the newly grown layer are of screw type with and this has been verified by comparison with ray tracing simulated images. TEDs with same and opposite sign of Burgers vector are found to be deflected on to the same basal plane by the overgrowth of macro-steps and they glide in the same and opposite directions respectively. TMDs deflected on to the basal plane by macro-steps get dissociated into c and a components, with the a segment undergoing glide to form V-shaped configurations.

4H-SiC substrates and homo-epitaxial layers were obtained using the traditional methods of physical vapor transport and chemical vapor deposition. Defect morphology has been studied using both Synchrotron White Beam X-ray Topography and Monochromatic Beam X-ray Topography. Molten KOH etching method was adopted to further investigate the dislocation behavior mechanisms. Deflected dislocations were observed at the periphery regions in both substrate and epitaxial wafers. 3C polytypes and half loop arrays were observed in the 4H-SiC epitaxial wafer. It is also found that the majority of basal plane dislocations are converted to threading edge dislocations in the epitaxial wafer samples. The proportion of BPD to TED conversion depends on the surface step morphology and growth mode in epitaxial growth which in turn depends on the C/Si ratio. By the optimization of etching time prior to epitaxy and C/Si ratio, high-quality epitaxial wafers with extremely low basal plane dislocations densities (＜0.1 cm-2) was obtained.

Synchrotron monochromatic beam X-ray topography (SMBXT) in grazing incidence geometry shows black and white contrast for basal plane dislocations (BPDs) with Burgers vectors of opposite signs as demonstrated using ray tracing simulations. The inhomogeneous distribution of these dislocations is associated with the concave/convex shape of the basal plane. Therefore, the distribution of these two BPD types were examined for several 6-inch diameter 4H-SiC substrates and the net BPD density distribution was used for evaluating the nature and magnitude of basal plane bending in these wafers. Results show different bending behaviors along the two radial directions - [110] and [100] directions, indicating the existence of non-isotropic bending. Linear mapping of the peak shift of the 0008 reflection along the two directions was carried out using HRXRD to correlate with the results from the SMBXT measurements. Basal-plane-tilt angle calculated using the net BPD density derived from SMBXT shows a good correlation with those obtained from HRXRD measurements, which further confirmed that bending in basal plane is caused by the non-uniform distribution of BPDs. Regions of severe bending were found to be associated with both large tilt angles (95% black contrast BPDs to 5% white contrast BPDs) and abrupt changes in a and c lattice parameters i.e. local strain.

Variations in nitrogen doping concentration across the PVT-grown 4H-SiC wafers can induce significant lattice strain, leading to degradation on the performance of SiC-based power devices. A qualitative study on the lattice strain variation in facet and off-facet regions was carried out for 4H-SiC substrates. The lattice strain maps for 4H-SiC wafers were derived from the 11-20, 1-100 (transmission geometry) and 0008 (reflection geometry) using synchrotron double crystal contour mapping method. Results show that the lattice strain within the basal plane is isotropic, while along [0001] direction, lattice strain is one order of magnitude lower, indicating elastic anisotropy of strain due to doping in 4H-SiC crystals. The distribution of lattice strain inside the facet region is more uniform than in the off-facet region. Measurement of nitrogen doping concentration by Hall effect measurements shows over 45% of difference in doping level between heavily doped facet region and off-facet region. Existence of significant lattice distortion in facet region of 4H-SiC substrates was further confirmed by X-ray rocking curve measurements.

Shifts in the spatial distribution of threading dislocations in 150 mm 4H SiC wafers were examined as a response to intentional changes in both the flow of the nitrogen source gas used to control resistivity during bulk crystal growth, and the growth rate. The density of threading edge and screw dislocations was found to be more evenly distributed in wafers produced under a high-growth rate, low-resistivity process. This result corresponded to a flattening of the resistivity distribution, and a ~34% reduction in on-and off-facet resistivity differential. The effect was attributed to regularized 4H island coalescence due to modulation of step terrace width.