WO2010119887A1 - Cu-Ga合金スパッタリングターゲットおよびその製造方法 - Google Patents
Cu-Ga合金スパッタリングターゲットおよびその製造方法 Download PDFInfo
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- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
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- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/22—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
- C23C14/34—Sputtering
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
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- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/22—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
- C23C14/34—Sputtering
- C23C14/3407—Cathode assembly for sputtering apparatus, e.g. Target
- C23C14/3414—Metallurgical or chemical aspects of target preparation, e.g. casting, powder metallurgy
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- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/12—Both compacting and sintering
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F9/00—Making metallic powder or suspensions thereof
- B22F9/02—Making metallic powder or suspensions thereof using physical processes
- B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
- B22F9/08—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
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- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
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- C22C1/00—Making non-ferrous alloys
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- C22C1/0425—Copper-based alloys
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- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
- B22F2998/10—Processes characterised by the sequence of their steps
Definitions
- the present invention relates to a Cu—Ga alloy sputtering target and a manufacturing method thereof, for example, a Cu—Ga alloy sputtering target used for forming a light absorption layer of a CIS (CIGS) thin film solar cell and a manufacturing method thereof. is there.
- a Cu—Ga alloy sputtering target used for forming a light absorption layer of a CIS (CIGS) thin film solar cell and a manufacturing method thereof. is there.
- a Cu—Ga alloy layer and an In layer are sequentially formed by a sputtering method and stacked (for example, see Patent Document 1).
- a sputtering target used for forming the Cu—Ga alloy layer for example, a sputtering target having a Ga content of 10 to 30 atomic% is generally used.
- the sputtering target for example, as shown in Patent Document 2, production by a melting / casting method can be mentioned.
- the cooling after casting proceeds relatively slowly, resulting in a large crystal structure and micro-uniformity of material components, resulting in composition in the in-plane direction and the plate thickness direction of the sputtering target.
- the composition of the resulting film is likely to change in the in-plane direction, which is considered to be a cause of a decrease in conversion efficiency of the solar cell.
- the sputtering target manufactured by the melting / casting method is likely to cause a composition variation in the thickness direction, and is considered to be a cause of variation among manufacturing lots.
- voids are easily generated in a sputtering target manufactured by a melting / casting method. If the porosity in the sputtering target is high, arcing (abnormal discharge) occurs at the edge of the pores during sputtering, and the discharge stability of sputtering deteriorates, or particles are generated by arcing shock, which adheres to the substrate. Thus, there is a problem that the adhesion between the film and the substrate is lowered, and the performance of the solar cell is deteriorated.
- the sputtering target manufactured by the melting / casting method has low strength, there is a problem that the target is easily cracked by the stress generated by the temperature rise of the target during sputtering.
- Japanese Patent No. 3249408 Japanese Unexamined Patent Publication No. 2000-073163 Japanese Unexamined Patent Publication No. 2008-138232 Japanese Unexamined Patent Publication No. 2008-163367
- the present invention has been made by paying attention to the above-described circumstances, and the object thereof is to form a Cu—Ga sputtering film excellent in the uniformity of film component composition (film uniformity), and to perform sputtering. It is an object of the present invention to provide a Cu—Ga alloy sputtering target that can reduce the occurrence of arcing therein and that has high strength and can suppress cracking during sputtering.
- the present invention includes the following aspects.
- the sputtering target is preferably a Cu—Ga alloy sputtering target substantially made of a Cu-based alloy containing Ga, and more preferably a Cu—Ga alloy sputtering target made only of a Cu-based alloy containing Ga.
- the proportion of the ⁇ phase based on the Cu 9 Ga 4 compound phase in an arbitrary line segment having a length of 100 ⁇ m is 20%.
- the Cu—Ga alloy sputtering target according to (1) or (2), wherein the number of ⁇ phases is 95% or less and based on the Cu 9 Ga 4 compound phase crossing the line segment is 5 or more. .
- the sputtering target is preferably substantially consisting of Cu 9 Ga 4 compound phase and Cu 3 Ga compound phase, Cu 9 Ga 4 be composed only of compound phase and Cu 3 Ga compound phase more preferred.
- For producing a Cu—Ga alloy sputtering target comprising:
- a Cu—Ga alloy sputtering target having fine crystal grains and reduced porosity, and preferably having a specific compound phase morphology.
- a Cu—Ga sputtering film having a uniform film composition for example, a CIS (CIGS) -based thin film, which suppresses arcing and cracking, is stable and efficient, and has a high yield. It can form as a layer which comprises the light absorption layer of a solar cell.
- CIS CIS
- FIG. 1 is a diagram showing a Cu—Ga binary system phase diagram.
- FIG. 2 is a microstructure photograph of the sputtering target of the present invention at a magnification of 500 times.
- FIG. 3 is a diagram illustrating a method for evaluating the form of the compound phase using FIG.
- FIG. 4 is a microstructural photograph of the comparative example sputtering target at a magnification of 500 times.
- FIG. 5 is a diagram for explaining a method for evaluating the form of the compound phase using FIG. 4. It is explanatory drawing which identified the compound phase by the X-ray diffraction method of the sputtering target of this invention.
- the present inventors diligently studied about countermeasures for solving the above-mentioned problems. As a result, it is possible to improve the homogeneity of the material by refining the crystal grains and reducing the porosity of the Cu—Ga alloy sputtering target, and preferably using the target if the form of the compound phase is as specified. It has been found that the uniformity of the film composition of the Cu—Ga sputtering film can be improved, the occurrence of arcing during sputtering can be reduced, and target cracking during sputtering can be suppressed.
- the sputtering target of the present invention will be described in detail.
- the sputtering target of the present invention is characterized in that the average crystal grain size is 10 ⁇ m or less and the porosity is 0.1% or less.
- the average crystal grain size is 10 ⁇ m or less.
- the average crystal grain size is preferably 8.0 ⁇ m or less. Note that the lower limit of the average crystal grain size is about 0.5 ⁇ m from the viewpoint of the production method and cost.
- the porosity is preferably 0.05% or less.
- the Ga content of the sputtering target of the present invention is desirably 20 atomic% or more and 29 atomic% or less. If the Ga content is less than 20%, the film uniformity may be deteriorated because the Cu phase is contained. On the other hand, when the Ga content exceeds 29%, a Cu 9 Ga 4 compound phase becomes a single phase, and there is a possibility that it is likely to break.
- a preferable Ga content is 24 atomic% or more and 26 atomic% or less.
- the sputtering target of the present invention preferably has an oxygen content of 500 ppm or less. By reducing the oxygen content in this way, the occurrence of arcing during sputtering can be further reduced.
- the oxygen content is more preferably 400 ppm or less.
- the form of the compound phase is preferably as follows. That is, based on Cu 9 Ga 4 called ⁇ phase illustrated in the Cu—Ga binary phase diagram of FIG. 1 in a 500 ⁇ magnification scanning electron microscope photograph of the surface of the sputtering target.
- the ratio of the intermetallic compound phase to an arbitrary line segment having a length of 100 ⁇ m is preferably 20% or more and 95% or less, and the number of the ⁇ phases crossing the line segment is preferably 5 or more.
- a more preferable ratio of the ⁇ phase to an arbitrary line segment having a length of 100 ⁇ m is 30% or more and 50% or less, and a more preferable number of the ⁇ phases crossing the line segment is 6 or more.
- a line (a short vertical line in FIG. 3) is drawn at the boundary between the light gray portion and the dark gray portion, and “Cu 9 occupying an arbitrary line segment having a length of 100 ⁇ m” is drawn.
- the “ratio of the ⁇ phase based on the Ga 4 compound phase” can be obtained by summing up the lengths of the line segments occupied by the light gray portions, obtaining the ratio of the total line segments, and converting it to a value per 100 ⁇ m.
- the direction of the line segment is not particularly limited.
- Examples of the compound phase constituting the Cu—Ga alloy sputtering target include a ⁇ phase based on Cu 3 Ga and a ⁇ phase based on Cu 9 Ga 4.
- the proportion of the ⁇ phase is 20%.
- the target crack in the said sputtering can fully be suppressed.
- the ⁇ phase is present in excess of 95%, it may approach the ⁇ single phase and be easily broken during sputtering.
- it is less than 20% a Cu phase appears and the film uniformity may be deteriorated.
- Scanning electron microscope observation photographs target observation photographs at a field size of 270 ⁇ m ⁇ 230 ⁇ m and a magnification of 500 times, and the average value of the ⁇ phase ratio is 20% or more when measured by the method shown in the examples described later. It is preferable that the average value of the number of ⁇ phases satisfies 5 or more. In the examples described later, three line segments in the same direction are measured in the observation photograph, but the direction of the line segments is not particularly limited.
- the present invention also defines a method for producing the sputtering target, the method comprising: A first step of gas atomizing and miniaturizing a molten Cu-based alloy containing Cu (Cu—Ga alloy); A second step of depositing the refined Cu—Ga alloy on a collector to obtain a Cu—Ga alloy preform; A third step of densifying the Cu—Ga alloy preform by a densification means to obtain a Cu—Ga alloy dense body; It is characterized by including.
- the composition and structure of the sputtering target can be made uniform. It is preferable because the above-described compound phase form can be realized.
- a Cu-based alloy containing Ga (Cu—Ga alloy, raw material) is heated to a melting point or higher to form a molten metal, the molten metal is caused to flow down from a nozzle, and gas is blown from the surroundings to the molten metal. Perform gas atomization to atomize.
- gas atomized and deposited particles that have been rapidly cooled from a semi-molten state to a semi-solid state to a solid state to form a predetermined shape (preform, intermediate before obtaining a final compact) Is obtained (second step).
- preform intermediate before obtaining a final compact
- second step gas atomized and deposited particles that have been rapidly cooled from a semi-molten state to a semi-solid state to a solid state to form a predetermined shape (preform, intermediate before obtaining a final compact)
- the molten Cu—Ga alloy obtained by melting in the range of approximately 1000 to 1300 ° C. is refined by gas atomization.
- the gas atomization the molten metal is caused to flow down from a nozzle, and an inert gas (for example, Ar or the like) or nitrogen gas is sprayed from the periphery of the molten metal to atomize the molten metal.
- the gas / metal ratio represented by the ratio of gas outflow / melt outflow can be, for example, 2.0 to 8.0 Nm 3 / kg.
- the average particle size of the particles (fine particles) atomized by the gas atomization is 200 ⁇ m or less, the fine particles are easily quenched, and the crystal structure in the fine particles is further increased. This is preferable because it becomes finer and the average crystal grain size of the target can be made smaller.
- the spray distance (distance from the nozzle tip to the collector center) is controlled within a range of 500 to 1000 mm, for example.
- the obtained Cu—Ga alloy preform is densified by densification means (third step).
- the densification means include sealing and densification by hot isostatic pressing (HIP).
- HIP hot isostatic pressing
- An example of the HIP condition is that the treatment is performed at a temperature of 400 to 600 ° C. under a pressure of 80 MPa or more for about 1 to 10 hours.
- the sputtering target of the present invention can be obtained by machining the dense Cu—Ga alloy.
- Nozzle provided at a lower portion of the induction melting furnace after obtaining a molten Cu—Ga alloy containing 25 atomic% of Ga and comprising the balance Cu and inevitable impurities by heating to 1200 ° C. in an induction melting furnace
- the gas metal ratio is 2.0 on a collector with an inclination angle of 35 °, which is made into fine droplets by spraying nitrogen gas onto the molten metal that has flowed out of the nozzle and rotating at a distance of 500 to 1000 mm (spray distance) from the nozzle.
- a Cu—Ga alloy preform (density: about 75% by volume) was produced by uniformly depositing at ⁇ 8.0 Nm 3 / kg.
- the Cu—Ga alloy preform produced by the spray forming method can be sealed and hot isostatically pressed (HIP) at a temperature of 500 ° C. to 600 ° C. under a pressure of 80 MPa or more to obtain a dense Cu—Ga alloy.
- HIP hot isostatically pressed
- the obtained dense body was machined to prepare a Cu—Ga alloy sputtering target (size: length 250 mm ⁇ width 250 mm ⁇ thickness 10 mm).
- Example 2 a Cu—Ga alloy sputtering target was prepared in the same manner as in Example 1 except that HIP was performed at a temperature of 400 ° C. to 500 ° C.
- Example 3 Cu—Ga alloy sputtering was performed by a spray forming method in the same manner as in Example 1 except that a molten Cu—Ga alloy containing 20 atomic% Ga and the balance Cu and inevitable impurities was used. A target was produced.
- Example 4 contains 29 atomic% of Ga, and a Cu—Ga alloy sputtering is performed by a spray forming method in the same manner as in Example 1 except that a molten Cu—Ga alloy composed of the balance Cu and inevitable impurities is used. A target was produced.
- the oxygen analysis amount of the obtained Cu—Ga alloy sputtering targets of Examples 1 to 4 was measured by an inert gas melting method and found to be 250 to 310 ppm. Further, the structure of the Cu—Ga alloy sputtering target produced in Example 1 was observed with a scanning electron microscope (SEM). The observation photograph (reflected electron image) is shown in FIG. In FIG. 2, a light gray portion indicates a ⁇ phase based on a Cu 9 Ga 4 compound phase, a dark gray portion indicates a ⁇ phase based on a Cu 3 Ga compound phase, and a black portion indicates pores (voids).
- the area ratio (%) of pores (for example, the black portion in FIG. 2 in the case of Example 1) occupying the microstructure photograph (field size: 270 ⁇ m ⁇ 230 ⁇ m) at a magnification of 500 times was defined as the porosity (%).
- Identification was performed using an X-ray diffractometer (RINT 1500 manufactured by Rigaku). The measurement conditions for the X-ray diffraction were as follows. ⁇ Scanning speed: 2 ° / min ⁇ Sampling width: 0.02 ° ⁇ Target output: 40kV, 200mA ⁇ Measurement range (2 ⁇ ): 20 ° -100 °
- the ratio of the ⁇ phase based on the Cu 9 Ga 4 compound phase occupying an arbitrary line segment having a length of 100 ⁇ m is the sum of the line segment lengths occupied by the light gray parts, and the ratio of the total line segment It calculated
- the number of ⁇ phases based on a Cu 9 Ga 4 compound phase crossing an arbitrary line segment having a length of 100 ⁇ m is the number of sections occupied by light gray portions among the sections separated by the vertical lines. It calculated
- a Cu—Ga sputtering film was formed on a glass substrate (size: 100 mm ⁇ 100 mm ⁇ 0.50 mm) by the DC magnetron sputtering method using the Cu—Ga alloy sputtering target.
- the conditions for the sputtering method were as follows. -Substrate temperature: room temperature-Ultimate vacuum: 3 x 10-5 Torr or less (1 x 10-3 Pa or less) ⁇ Gas pressure during film formation: 1 to 4 mTorr DC sputtering power density (DC sputtering power per unit area of target): 1.0 to 20 W / cm 2
- the sheet resistance at any nine locations within the same film surface on the glass substrate was measured. Then, the case where all the values at 9 locations are within ⁇ 3% of the average value at 9 locations is defined as A (film uniformity is good), and at least one of the 9 locations is ⁇ 3 from the average value at 9 locations. The case of exceeding% was evaluated as C (film uniformity was poor). The results are shown in Table 1.
- the film uniformity, arcing occurrence, and crack occurrence are all A, and the film uniformity, arcing occurrence, crack occurrence is one or more C. C, and other than that B.
- Comparative Example 1 a Cu—Ga alloy sputtering target was produced by the spray forming method in the same manner as in Example 1 except that the gas metal ratio was 1.0 Nm 3 / kg. Then, the average crystal grain size, porosity, identification of the compound phase, and measurement of the form of the compound phase, evaluation of film uniformity, evaluation of occurrence of arcing, and evaluation of generation of cracks of this Cu—Ga alloy sputtering target, It carried out like the said Example. The results are also shown in Table 1.
- Comparative Example 2 In Comparative Example 2, a Cu—Ga alloy sputtering target was produced by the spray forming method in the same manner as in Example 1 except that the HIP pressure was 40 MPa. Then, the average crystal grain size, porosity, identification of the compound phase, and measurement of the form of the compound phase, evaluation of film uniformity, evaluation of occurrence of arcing, and evaluation of generation of cracks of this Cu—Ga alloy sputtering target, It carried out like the said Example. The results are also shown in Table 1.
- FIG. 4 The structure of this Cu—Ga alloy sputtering target was observed with a scanning electron microscope (SEM).
- SEM scanning electron microscope
- FIG. 4 The observation photograph (reflected electron image) is shown in FIG.
- the light gray portion is the ⁇ phase based on the Cu 9 Ga 4 compound phase
- the dark gray portion is the ⁇ phase based on the Cu 3 Ga compound phase
- the black portion is a pore (void). ).
- Comparative Example 5 a Cu—Ga alloy sputtering target was formed by a spray forming method in the same manner as in Example 1 except that a molten Cu—Ga alloy containing 15 atomic% Ga and the balance Cu and inevitable impurities was used. Was made. Then, the average crystal grain size, porosity, identification of the compound phase and measurement of the form of the compound phase, evaluation of film uniformity, evaluation of occurrence of arcing, and evaluation of occurrence of cracking of the Cu—Ga alloy sputtering target It carried out like the Example. The results are also shown in Table 1.
- Comparative Example 6 a Cu—Ga alloy sputtering target was formed by a spray forming method in the same manner as in Example 1 except that a molten Cu—Ga alloy containing 35 atomic% Ga and the balance Cu and inevitable impurities was used. Was made. Then, the average crystal grain size, porosity, identification of the compound phase and measurement of the form of the compound phase, evaluation of film uniformity, evaluation of occurrence of arcing, and evaluation of occurrence of cracking of the Cu—Ga alloy sputtering target It carried out like the Example. The results are also shown in Table 1.
- the Cu—Ga alloy sputtering target of the present invention that satisfies the prescribed requirements is compared with the sputtering target produced by the conventional method (the melting method of Comparative Example 3 and the powder sintering method of Comparative Example 4).
- the crystal grains are fine and uniform, and there are few pores.
- the arcing frequency during sputtering is low, cracking does not occur until the life end, and the yield of using the target is high.
- the film uniformity of the resulting sputtering film is good.
- the spray forming method defined in the method of the present invention it is desirable to control the conditions such as gas metal ratio, HIP pressure, HIP temperature, etc. so as to satisfy the defined requirements such as average crystal grain size and porosity. I understand.
- Comparative Example 1 the average crystal grain size did not satisfy the requirements of the present invention and the film uniformity was poor.
- Comparative Example 2 the porosity did not satisfy the requirements of the present invention, the arcing frequency was high, and the sputtering was poor.
- Comparative Example 5 the Ga content and the average crystal grain size did not satisfy the requirements of the present invention, and the film uniformity was poor.
- Comparative Example 6 the Ga content and the ratio of the ⁇ phase did not satisfy the requirements of the present invention, and cracking occurred due to the life end.
- a Cu—Ga alloy sputtering target having fine crystal grains and reduced porosity, and preferably having a specific compound phase morphology.
- a Cu—Ga sputtering film having a uniform film composition for example, a CIS (CIGS) -based thin film, which suppresses arcing and cracking, is stable and efficient, and has a high yield. It can form as a layer which comprises the light absorption layer of a solar cell.
- CIS CIS
Abstract
Description
(1)Gaを含むCu基合金を含むスパッタリングターゲットであって、その平均結晶粒径が10μm以下であり、かつ気孔率が0.1%以下であるCu-Ga合金スパッタリングターゲット。
上記スパッタリングターゲットは、Gaを含むCu基合金から実質的になるCu-Ga合金スパッタリングターゲットであることが好ましく、Gaを含むCu基合金からのみなるCu-Ga合金スパッタリングターゲットであることがさらに好ましい。
(2)Ga含有量が20原子%以上、29原子%以下である(1)に記載のCu-Ga合金スパッタリングターゲット。
(3)前記スパッタリングターゲットの表面を撮影した倍率500倍の走査型電子顕微鏡観察写真において、長さ100μmの任意の線分に占めるCu9Ga4化合物相を基とするγ相の比率が20%以上、95%以下であり、かつ上記線分を横切るCu9Ga4化合物相を基とするγ相の個数が5個以上である(1)または(2)に記載のCu-Ga合金スパッタリングターゲット。
(4)Cu9Ga4化合物相とCu3Ga化合物相を含む(1)~(3)のいずれかに記載のCu-Ga合金スパッタリングターゲット。
上記スパッタリングターゲットは、Cu9Ga4化合物相とCu3Ga化合物相から実質的になることが好ましく、Cu9Ga4化合物相とCu3Ga化合物相からのみなることがさらに好ましい。
(5)(1)~(4)のいずれかに記載のCu-Ga合金スパッタリングターゲットの製造方法であって、
Gaを含むCu基合金の溶湯をガスアトマイズし、微細化する第1の工程と、
前記微細化したCu-Ga合金をコレクターに堆積して、Cu-Ga合金プリフォームを得る第2の工程と、
前記Cu-Ga合金プリフォームを緻密化手段によって緻密化し、Cu-Ga合金緻密体を得る第3の工程と、
を包含するCu-Ga合金スパッタリングターゲットの製造方法。
スパッタリングターゲットの表面を撮影した倍率500倍の走査型電子顕微鏡観察写真(反射電子像)において、長さ100μmの任意の線分に占めるCu9Ga4化合物相を基とするγ相の比率と、上記線分を横切るCu9Ga4化合物相を基とするγ相の個数は、例えば、実施例1の場合について、前記図2に線分を引いた図3を用いて説明すると、図3における任意の線分(約270μm)について、上記薄い灰色部分と濃い灰色部分の境界に線(図3においては、短い縦線)を引き、そして、「長さ100μmの任意の線分に占めるCu9Ga4化合物相を基とするγ相の比率」は、薄い灰色部分が占める線分長さを合計して、全線分に占める割合を求め、100μmあたりの値に換算することによって求めることができ、また、「長さ100μmの任意の線分を横切るCu9Ga4化合物相を基とするγ相の個数」は、上記縦線で区切られた区画のうち、薄い灰色部分が占める区画の個数を求め、100μmあたりの値に換算することによって求めることができる。また、図3に示すように、任意の3本の線分の相の比率・個数を、上記の通りそれぞれ求めて平均値を算出して求めてもよい。なお、線分の方向については特に問わない。
本発明は、上記スパッタリングターゲットの製造方法も規定するものであって、該方法は、
・Gaを含むCu基合金(Cu-Ga合金)の溶湯をガスアトマイズし、微細化する第1の工程と、
・前記微細化したCu-Ga合金をコレクターに堆積して、Cu-Ga合金プリフォームを得る第2の工程と、
・前記Cu-Ga合金プリフォームを緻密化手段によって緻密化し、Cu-Ga合金緻密体を得る第3の工程と、
を包含するところに特徴を有する。特には、上記方法(特に、上記Gaを含むCu基合金の溶湯をガスアトマイズさせながら、コレクターに堆積させるスプレイフォーミング法を含む方法)を採用すれば、スパッタリングターゲットの成分組成や組織を均一にできるとともに、上述した化合物相の形態を実現することもできるので好ましい。
Gaを25原子%含有し、残部Cuおよび不可避不純物からなるCu-Ga合金の溶湯を、誘導溶解炉で1200℃に加熱して得た後、この溶湯を、誘導溶解炉の下部に設けたノズルから流出させ、流出した溶湯に窒素ガスを吹き付けることで、微細な液滴とし、ノズルから500~1000mmの距離(スプレイ距離)で回転している傾斜角度35°のコレクターにガスメタル比2.0~8.0Nm3/kgで均等に降り積もらせ、Cu-Ga合金プリフォーム(密度:約75体積%)を作製した。前記スプレイフォーミング法によって作製したCu-Ga合金プリフォームを、封缶して500℃~600℃の温度下、80MPa以上の圧力下で熱間静水圧プレス(HIP)し、Cu-Ga合金緻密体を得た。
上記Cu-Ga合金スパッタリングターゲットから切り出した試験片を用いて、表面研磨を行い、次いでエッチング液(塩化第二鉄+塩酸+水)を用いて表面をエッチングし、試料を用意した。そしてこの試料をSEMで観察・撮影し、倍率500倍のミクロ組織写真(視野サイズ:270μm×230μm、1視野)を用いて、JISH 0501の伸銅品結晶粒度試験方法に記載の切断法により、結晶粒数と切断長さを測定して算出した平均値を平均結晶粒径とした。
上記倍率500倍のミクロ組織写真(視野サイズ:270μm×230μm)に占める気孔(例えば実施例1の場合は、図2における黒色部分)の面積率(%)を、気孔率(%)とした。
X線回折装置(リガク製RINT1500)を用いて同定を行った。
上記、X線回折の測定条件は下記の通りとした。
・走査速度:2°/min
・サンプリング幅:0.02°
・ターゲット出力:40kV、200mA
・測定範囲(2θ):20°~100°
前記スパッタリングターゲットの表面を撮影した倍率500倍の走査型電子顕微鏡観察写真(反射電子像)において、長さ100μmの任意の線分に占めるCu9Ga4化合物相を基とするγ相の比率と、上記線分を横切るCu9Ga4化合物相を基とするγ相の個数を求めた。その例として、実施例1の場合について、前記図2に線分を引いた図3を用いて説明する。図3における任意の線分(約270μm)について、上記薄い灰色部分と濃い灰色部分の境界に線(図3においては、短い縦線)を引いた。そして、「長さ100μmの任意の線分に占めるCu9Ga4化合物相を基とするγ相の比率」は、薄い灰色部分が占める線分長さを合計して、全線分に占める割合を求め、100μmあたりの値に換算した。また、「長さ100μmの任意の線分を横切るCu9Ga4化合物相を基とするγ相の個数」は、上記縦線で区切られた区画のうち、薄い灰色部分が占める区画の個数を求め、100μmあたりの値に換算した。そして、図3に示す通り、任意の3本の線分の相の比率・個数を、上記の通りそれぞれ求めて平均値を算出した。
上記Cu-Ga合金スパッタリングターゲットを用い、DCマグネトロンスパッタリング法で、ガラス基板(サイズ:100mm×100mm×0.50mm)上に、Cu-Gaスパッタリング膜を形成した。
・基板温度:室温
・到達真空度:3×10-5Torr以下(1×10-3Pa以下)
・成膜時のガス圧:1~4mTorr
・DCスパッタリングパワー密度(ターゲットの単位面積当たりのDCスパッタリングパワー):1.0~20W/cm2
また、上記膜均一性の評価におけるDCマグネトロンスパッタリング時に、スパッタリング装置の電気回路に接続したアークモニターにより、アーキングの発生数をカウントした。アーキング発生数のカウントは、10分間のプリスパッタ後の10分間のスパッタリングで行った。そして、アーキング発生数が10回以上の場合をC(スパッタ不良状態)とし、アーキング発生数が9回以下の場合をA(スパッタ良好状態)と評価した。その結果を表1に示す。
上記Cu-Ga合金スパッタリングターゲット用いてDCマグネトロンスパッタリングを繰り返し行い、スパッタリングターゲット表面エロージョン最深部におけるターゲット残厚が1mmになった場合を「ライフエンド」とし、このライフエンドまでに完全に割れた場合をC、割れの程度が微小であった場合をB、上記ライフエンドまで割れが生じなかった場合をAと評価した。その結果を表1に示す。
比較例1は、ガスメタル比を1.0Nm3/kgとする以外は実施例1と同様にして、スプレイフォーミング法によりCu-Ga合金スパッタリングターゲットを作製した。そして、このCu-Ga合金スパッタリングターゲットの平均結晶粒径、気孔率、化合物相の同定、および化合物相の形態の測定、ならびに膜均一性の評価、アーキング発生の評価、および割れ発生の評価を、上記実施例と同様にして行った。その結果を表1に併記する。
比較例2は、HIP圧力を40MPaとする以外は実施例1と同様にして、スプレイフォーミング法によりCu-Ga合金スパッタリングターゲットを作製した。そして、このCu-Ga合金スパッタリングターゲットの平均結晶粒径、気孔率、化合物相の同定、および化合物相の形態の測定、ならびに膜均一性の評価、アーキング発生の評価、および割れ発生の評価を、上記実施例と同様にして行った。その結果を表1に併記する。
Gaを25原子%含有し、残部Cuおよび不可避不純物からなるCu-Ga合金の溶湯を、鋳型に鋳造してインゴットを作製した。得られたインゴットを機械加工し、Cu-Ga合金スパッタリングターゲットを作製した(溶解法)。
Gaを25原子%含有し、残部Cuおよび不可避不純物からなるCu-Ga合金の溶湯を、鋳型に鋳造してインゴットを作製した。得られたインゴットを粉砕し、焼結してCu-Ga合金スパッタリングターゲットを作製した(粉末焼結法)。
比較例5は、Gaを15原子%含有し、残部Cuおよび不可避不純物からなるCu-Ga合金の溶湯を用いた以外は、実施例1と同様にして、スプレイフォーミング法によりCu-Ga合金スパッタリングターゲットを作製した。そして、このCu-Ga合金スパッタリングターゲットの平均結晶粒径、気孔率、化合物相の同定および化合物相の形態の測定、ならびに膜均一性の評価、アーキング発生の評価、および割れ発生の評価を、上記実施例と同様にして行った。その結果を表1に併記する。
比較例6は、Gaを35原子%含有し、残部Cuおよび不可避不純物からなるCu-Ga合金の溶湯を用いた以外は、実施例1と同様にして、スプレイフォーミング法によりCu-Ga合金スパッタリングターゲットを作製した。そして、このCu-Ga合金スパッタリングターゲットの平均結晶粒径、気孔率、化合物相の同定および化合物相の形態の測定、ならびに膜均一性の評価、アーキング発生の評価、および割れ発生の評価を、上記実施例と同様にして行った。その結果を表1に併記する。
本出願は、2009年4月14日出願の日本特許出願(特願2009-098481)、2010年3月17日出願の日本特許出願(特願2010-061280)に基づくものであり、その内容はここに参照として取り込まれる。
Claims (5)
- Gaを含むCu基合金を含むスパッタリングターゲットであって、その平均結晶粒径が10μm以下であり、かつ気孔率が0.1%以下であるCu-Ga合金スパッタリングターゲット。
- Ga含有量が20原子%以上、29原子%以下である請求項1に記載のCu-Ga合金スパッタリングターゲット。
- 前記スパッタリングターゲットの表面を撮影した倍率500倍の走査型電子顕微鏡観察写真において、長さ100μmの任意の線分に占めるCu9Ga4化合物相を基とするγ相の比率が20%以上、95%以下であり、かつ上記線分を横切るCu9Ga4化合物相を基とするγ相の個数が5個以上である請求項1に記載のCu-Ga合金スパッタリングターゲット。
- Cu9Ga4化合物相とCu3Ga化合物相を含む請求項1に記載のCu-Ga合金スパッタリングターゲット。
- 請求項1~4のいずれかに記載のCu-Ga合金スパッタリングターゲットの製造方法であって、
Gaを含むCu基合金の溶湯をガスアトマイズし、微細化する第1の工程と、
前記微細化したCu-Ga合金をコレクターに堆積して、Cu-Ga合金プリフォームを得る第2の工程と、
前記Cu-Ga合金プリフォームを緻密化手段によって緻密化し、Cu-Ga合金緻密体を得る第3の工程と、
を包含するCu-Ga合金スパッタリングターゲットの製造方法。
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2010
- 2010-03-17 JP JP2010061280A patent/JP5643524B2/ja not_active Expired - Fee Related
- 2010-04-14 TW TW099111625A patent/TWI444489B/zh not_active IP Right Cessation
- 2010-04-14 WO PCT/JP2010/056658 patent/WO2010119887A1/ja active Application Filing
- 2010-04-14 US US13/263,992 patent/US20120045360A1/en not_active Abandoned
- 2010-04-14 KR KR1020117024041A patent/KR20120000080A/ko not_active Application Discontinuation
- 2010-04-14 CN CN2010800113832A patent/CN102362002B/zh not_active Expired - Fee Related
- 2010-04-14 EP EP10764471.8A patent/EP2420590A4/en not_active Withdrawn
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Cited By (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP2012031508A (ja) * | 2010-06-28 | 2012-02-16 | Hitachi Metals Ltd | Cu−Ga合金ターゲット材およびその製造方法 |
JP2012201948A (ja) * | 2011-03-25 | 2012-10-22 | Sumitomo Metal Mining Co Ltd | Cu−Ga合金スパッタリングターゲット |
EP2505686A1 (en) * | 2011-04-01 | 2012-10-03 | Sanyo Special Steel Co., Ltd. | Cu-Ga-based alloy powder with low oxygen content, Cu-Ga-based alloy target material and method for producing the target material |
CN103930591A (zh) * | 2011-10-14 | 2014-07-16 | 株式会社爱发科 | 靶组合件及其制造方法 |
JP2014084515A (ja) * | 2012-10-25 | 2014-05-12 | Sumitomo Metal Mining Co Ltd | Cu−Ga合金スパッタリングターゲットの製造方法及びCu−Ga合金スパッタリングターゲット |
Also Published As
Publication number | Publication date |
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US20120045360A1 (en) | 2012-02-23 |
TWI444489B (zh) | 2014-07-11 |
EP2420590A4 (en) | 2014-07-23 |
CN102362002A (zh) | 2012-02-22 |
JP5643524B2 (ja) | 2014-12-17 |
TW201114933A (en) | 2011-05-01 |
JP2010265544A (ja) | 2010-11-25 |
EP2420590A1 (en) | 2012-02-22 |
KR20120000080A (ko) | 2012-01-03 |
CN102362002B (zh) | 2013-12-25 |
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