Deposition of novel nanocomposite films by a newly developed differential pumping co-sputtering system

A differential pumping co-sputtering system was developed to facilitate a controlled, but flexible fabrication of multifunctional nanocomposite films with compositions not limited by thermodynamic restrictions. This system features a multichamber design with a differential pumping system. Dividing atmospheres with this set up greatly reduced the cross-contamination between chambers, and each material could be co-deposited by rapid rotation of the substrate. The clearance between the substrate holder and the chamber was set at 1-2 mm, and the conductance of the clearance was examined roughly using conductance equations for typical types of orifices. It was found that the potential difference (PD) value of the clearance between the two chambers was less than 0.01; the gas flow between the two chambers through the clearance thus appears to be a practical molecular flow. The PD value, where P is a pressure (Pa) and D is a diameter of an orifice or a pipe (m), is a gas flow indicator or parameter obtained from an equation of Knudsen number. The changes in the oxygen partial pressure and glow discharge plasma in the left chamber were investigated using a process gas monitor (PGM) and optical emission spectroscope (OES) by introducing different gases to each chamber. The PGM results revealed that the cross-contamination of oxygen from the other chamber was suppressed to 10 3 of the original. In addition, the OES measurement for glow discharge plasma did not detect substantial oxygen contamination from the other chamber. Using the newly developed system, an AlNSiO _x nanocomposite film consisting of B4-type AlN and amorphous SiO _x was obtained successfully.