Epitaxial Growth and Characterization of SiC for High Power Devices

Sammanfattning: Silicon Carbide (SiC) is a semiconductor with a set of superior properties, including wide bandgap, high thermal conductivity, high critical electric field and high electron mobility. This makes it an excellent material for unipolar and bipolar electronic device applications that can operate under high temperature and high power conditions. Despite major advancements in SiC bulk growth technology, during last decade, the crystalline quality of bulk grown material is still not good enough to be used as the active device structure. Also, doping of the material through high temperature diffusion is not possible while ion implantation leads to severe damage to the crystalline quality of the material. Therefore, to exploit the superior quality of the material, epitaxial growth is a preferred technology for the active layers in SiC-based devices. Horizontal Hot-wall chemical vapor deposition is probably the best way to produce high quality epitaxial layers where complete device structure with different doping type or concentrations can be grown during a single growth run.SiC exists in many different polytypes and to maintain the polytype stability during epitaxial growth, off-cut substrates are required to utilize step-flow growth. The major disadvantage of growth on off-cut substrates is the replication of basal plane dislocations from the substrate into the epilayer. These are known to be the main source of degradation of bipolar devices during forward current injection. The bipolar degradation is caused by expanding stacking faults which increases the resistance and leads to fatal damage to the device. Structural defects replicated from the substrate are also important for the formation of defects in the epitaxial layer. In this thesis we have developed an epitaxial growth process to reduce the basal plane dislocations and the bipolar degradation. We have further studied the properties of the epitaxial layer with a focus on morphological defects and structural defects in the epitaxial layer.The approach to avoid basal plane dislocation penetration from the substrate is to grow on nominally on-axis substrate. The main obstacle with on-axis growth is to avoid the formation of parasitic 3C polytype inclusions. The first results (Paper 1) on epitaxial growth on nominally on-axis Si-face substrates showed that the 3C inclusions nucleated at the beginning of the growth and expand laterally without following any particular crystallographic direction. Also, the extended defects in the substrate like micropipes, clusters of threading screw and edge dislocations do not give rise to 3C inclusion. The substrate surface damage was instead found to be the main source. To improve the starting surface different in-situ etching conditions were studied (Paper 2) and Si-rich conditions were found to effectively remove the substrate surface damages with lowest roughness and more importantly uniform distribution of steps on the surface. Therefore, in-situ etching under Si-rich conditions was performed before epitaxial growth. Using this 100 % 4H polytype was obtained in the epilayer on full 2” wafer (Paper 3) using an improved set of growth parameters with Si-rich conditions at the beginning of the growth. Simple PiN diodes were processed on the on-axis material, and tested for bipolar degradation. More than 70 % of these (Paper 4) showed a stable forward voltage drop during constant high current injection.High voltage power devices require thick epitaxial layers with low doping. In addition, the high current needs large area devices with a reduced number of defects. Growth and properties of thick epilayers have been studied in details (Paper 5) and the process parameters in Horizontal Hotwall chemical vapor deposition reactor are found to be stable during the growth of over 100 µm thick epilayers.An extensive study of epitaxial defect known as the carrot defect has been conducted to investigate the structure of the defect and its probable relation to the extended defects in the substrate (Paper 6). Other epitaxial defects observed and studied were different in-grown stacking faults which frequently occur in as-grown epilayers (Paper 7) and also play an important role in the device performance. Minority carrier lifetime is an important property especially for high power bipolar devices. The influence of structural defects on minority carrier lifetime has been studied (Paper 8) in several epilayers, using a unique high resolution photoluminescence decay mapping. The technique has shown the influence on carrier lifetime from different structural defects, and also revealed the presence of non-visible structural defects such as dislocations and stacking faults, normally not observed with standard techniques.