In-situ growth mode control of AlN on SiC substrate by sublimation closed space technique

For the growth of AlN single crystal with large diameter and low dislocation density on SiC substrate by physical vapor transport (PVT), a dislocation blocking buffer layer (DBBL) has been simply developed by optimizing the AlN growth parameters such as temperature gradient (ΔT), substrate temperature (Tsub), and N2 partial pressure (PN2) at the initial growth stage. Increase in ΔT resulted in the formation of an abrupt AlN/SiC interface due to the suppression of inhomogeneous thermal decomposition at the interface and the subsequent AlN unstable island growth. The well-defined AlN/SiC interface played an important role in controlling the two kinds of different AlN growth mode in-situ as functions of Tsub and PN2. One is a continuous step-flow growth mode, and the other is a discontinuous platelet-like growth. The discontinuous AlN layer, consisting of thin AlN platelets and air-gaps inserted between the two adjacent platelets, acted as the DBBL. By introducing the DBBL at the initial growth stage, followed by the step-flow growth, continuous AlN layer with dislocation density of 1.7 × 106 cm−2 was achieved at a total growth thickness of 60 μm, which is two orders of magnitude lower than the previously reported value.