Methods to deposit controlled thin layers of transition metal dichalcogenides

Abstract

Transition metal dichalcogenides (TMDs) are deposited as thin layers on a substrate. The TMDs may be grown on oxide substrates and may have a tunable TMD-oxide interface.

Claims

1. A method of preparing a substrate comprising: performing an a atomic layer deposition cycle exposure for a transition metal precursor at a first deposition temperature between 50° C. and 300° C. above a sublimation temperature of the transition metal precursor; performing a b atomic layer deposition cycle exposure for a sulfur precursor at a second deposition temperature between 50° C. and 300° C. above a sublimation temperature of the sulfur precursor; performing z supercycles of the a atomic layer deposition cycle and of the b atomic layer deposition cycle; and forming a transition metal dichalcogenide coating; wherein the transition metal precursor comprises MoF.sub.6 and the sulfur precursor is H.sub.2S with the transition metal dichalcogenide being MoS.sub.2 or wherein the transition metal precursor is tetrakis(dimethylamido) hafnium or HfCl.sub.4 and the sulfur precursor is H.sub.2S, with the transition metal dichalcogenide being HfS.sub.2.

2. The method of claim 1, wherein the a cycles each comprise: a 1 second dose followed by a gas purge.

3. The method of claim 1, wherein the b cycle depositions each comprise: a 1 second dose followed by a second gas purge.

4. The method of claim 1, wherein the first deposition temperature and the second disposition temperature are the same.

5. The method of claim 1, wherein the first deposition temperature is between 100° C. and 300° C.

6. The method of claim 1, wherein the second deposition temperature is between 50° C. and 300° C.

7. The method of claim 1, further comprising, after forming the transition metal dichalcogenide: performing a c atomic layer deposition cycle of a second transition metal precursor at a third deposition temperature between 100° C. and 300° C.; performing a d atomic layer deposition cycle of a second reducing precursor at a fourth deposition temperature between 100° C. and 300° C., and performing y supercycles of the c atomic layer deposition cycle and of the d atomic layer deposition cycle, forming a transition metal coating on the transition metal dichalcogenide.

8. A method of forming a transition metal oxide and transition metal dichalcogenide stack comprising: exposing a first transition metal precursor at a first deposition temperature between 50° C. and 400° C.; exposing an oxidizing precursor at a second deposition temperature between 50° C. and 400° C.; depositing a layer of transition metal oxide; exposing a second transition metal precursor at a third deposition temperature between 50° C. and 400° C.; exposing a sulfur precursor at a fourth deposition temperature between 50° C. and 400° C.; and depositing a transition metal dichalcogenide on the transition metal oxide; wherein the second transition metal precursor is tetrakis(dimethylamido) hafnium or HfCl.sub.4 and the sulfur precursor is H.sub.2S, with the transition metal dichalcogenide being HfS.sub.2.

9. The method of claim 8, wherein the first transition metal precursor and the second transition metal precursor are different.

10. The method of claim 8, wherein the first transition metal precursor and the second transition metal precursor are the same.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) The foregoing and other features of the present disclosure will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only several implementations in accordance with the disclosure and are therefore, not to be considered limiting of its scope, the disclosure will be described with additional specificity and detail through use of the accompanying drawings.

(2) FIGS. 1A-1B show in situ quartz crystal microbalance (QCM) measurements during molybdenum sulfide atomic layer deposition (ALD) at 200° C. using the timing sequence (1.5-15-1.5-15 s) over 19 ALD cycles (FIG. 1A) and expanded view of two successive ALD cycles (FIG. 1B). The molybdenum hexafluoride (MoF.sub.6) and hydrogen sulfide (H.sub.2S) dosing periods are indicated at the bottom of the graphs.

(3) FIGS. 2A-2B show QCM data for molybdenum sulfide ALD varying MoF.sub.6 dose time (FIG. 2A) and H.sub.2S dose time (FIG. 2B) using 5 s purge times and a constant 1 s dose times for the other precursor in both cases. Prior to these measurements, MoF.sub.6 and H.sub.2S were pulsed using a (1.5-15-1.5-15 s) timing sequence until steady state growth was achieved at 200° C.

(4) FIGS. 3A-3B show results for an embodiment of deposited TMD. FIG. 3A shows a graph of film thickness as a function of MoS.sub.2 ALD cycles as measured by ellipsometry. FIG. 3B is a scanning electron microscopy (SEM) image of an as-deposited film after 600 cycles with a thickness of 45 nm (left) and annealed film (right). The inset of FIG. 3B shows a higher resolution SEM image of the as-deposited film. ALD reaction was carried out at 200° C.

(5) FIG. 4A is a Raman spectrum using a 514 nm excitation laser showing the as-deposited film (lower), which exhibits a MoS.sub.3 peak at 435 cm.sup.−1 and the annealed sample (upper) featuring clear MoS.sub.2 fundamental peaks. FIG. 4B is an X-ray diffraction pattern of the as-deposited and annealed sample. After annealing, the (002) reflection associated with the layered structure of MoS.sub.2 is seen.

(6) FIGS. 5A-5B show X-ray photoelectron spectroscopy (XPS) survey spectra of as-deposited ALD MoS.sub.x film (FIG. 5A) and same film after annealing in H.sub.2 (FIG. 5B).

(7) FIGS. 6A-6D show high resolution XPS scans for Mo 3d as deposited (FIG. 6A), Mo 3d after anneal (FIG. 6B), S 2p as-deposited (FIG. 6C), and S 2p after anneal (FIG. 6D).

(8) FIG. 7A shows ultraviolet-visible (UV-vis) transmission measurements of ALD MoS.sub.2 films on fused silica substrates. Clear absorption of the resulting film is seen. FIG. 7B is a linear regression in the Tauc-plot of the 12 nm sample. A band-gap of approximately 1.3 eV was found.

(9) FIG. 8A shows QCM thickness vs ALD cycles for the repeated sequence of 2 cycles zinc sulfide (ZnS) ALD followed by 20 cycles MoS.sub.2 ALD. FIG. 8B is an expanded view of cycles 9-13 plotted as thickness vs time, highlighting the detailed mass changes during the transition from ZnS ALD to MoS.sub.2 ALD. The diethyl zinc (DEZ), MoF.sub.6, and H.sub.2S dosing times are indicated by the traces at the bottom of the graph.

(10) FIG. 9A shows QCM data for hafnium sulfide (HfS.sub.2)-hafnium oxide (HfO.sub.2) ALD using 10 s purge times and a constant 1 s dose times for the other precursor in both cases at 200° C. where the Hf precursor is tetrakis(dimethylamido) hafnium (TDMA-Hf). FIGS. 9B-9D show QCM data magnified for a few ALD cycles of HfO.sub.2—HfS.sub.2 at the interface from FIG. 9a. QCM data for HfO.sub.2—HfS.sub.2—HfO.sub.2 used 10 s purge times and a constant 1 s dose times for the other precursor in both cases.

(11) FIGS. 10A-10B show QCM data for magnesium sulfide (MgS.sub.2) recorded using 10 s purge times and a constant 2 s dose times for bis-cyclopentadienyl magnesium (MgCp.sub.2) and 0.5 s for H.sub.2S precursors at 200° C. FIG. 10B shows QCM data magnified for a few ALD cycles from FIG. 10A. QCM data for MgS.sub.2 10 s purge times and a constant 2 s dose times for MgCp.sub.2 and 0.5 s for H.sub.2S precursors.

(12) FIG. 11A shows QCM data for MoS.sub.2—Mo—MoS.sub.2 layers stack grown with 10 s purge times and 1 s dose times for the all MoF.sub.6, disilane (Si.sub.2H.sub.6), and H.sub.2S precursors at 200° C. FIG. 11B shows expanded view QCM data for a MoS.sub.2—Mo bilayer from FIG. 11A. FIG. 11C shows expanded view QCM data for a Mo—MoS.sub.2 bilayer from FIG. 11A.

(13) FIGS. 12A-12B are taken from the reference: Journal of Vacuum Science & Technology A: Vacuum, Surfaces, and Films 33, 020802 (2015). FIG. 12A schematically depicts different etching behavior for a hypothetical thin film versus dosing time of the etching precursor where graph (a) is atomic layer etching (ALE), (d) is continuous etching, and (b) and (c) are intermediate cases where the behavior is mostly ALE, but some continuous etching is observed also. FIG. 12B shows a schematic for a hypothetical ALE process using etching chemicals A and B, where A prepares the surface for etching and B performs the actual etching.

(14) FIG. 13 shows QCM data recorded during the pulsed chemical vapor deposition (CVD) of Mo using successive MoF.sub.6 exposures where each MoF.sub.6 exposure deposits a fixed mass of Mo on the sensor

(15) FIG. 14 shows QCM data for MoF.sub.6—H.sub.2O dosing with cycle times of (15-20-5-20 s) on a substrate at 200° C. showing a net mass gain during each MoF.sub.6 exposure and a mass loss during the subsequent H.sub.2O exposure such that the net mass gain from one MoF.sub.6—H.sub.2O cycle is negative.

(16) FIGS. 15A-15B relate to an embodiment of TCD deposition using MoF.sub.6 and H.sub.2S. FIG. 15A shows QCM at 200° C. for MoS.sub.2 ALD using MoF.sub.6 and H.sub.2S from 0-450 s, followed by MoS.sub.2 ALE using MoF.sub.6 and H.sub.2O. Each MoF.sub.6 and H.sub.2O exposure is divided into numerous microdoses of the same precursor in succession to illustrate that the ALE is self-limiting for both the MoF.sub.6 and H.sub.2O steps. FIG. 15B demonstrates saturation of the MoS.sub.2 ALD process as a function of both the MoF.sub.6 and H.sub.2O dose times. For both precursors, the purge time is kept constant at 20 s. Prior to etching experiment, ALD MoS.sub.2 is performed with MoF.sub.6 and H.sub.2S were pulsed using ALD cycle of (MoF.sub.6—N.sub.2—H.sub.2S—N.sub.2)=(1-10-1-10 s) timing sequence until steady state growth was achieved at 200° C.

(17) FIG. 16 shows QCM data for multiple iterations of MoS.sub.2 ALD followed by MoS.sub.2 ALE at 200° C. ALD MoS.sub.2 was performed with MoF.sub.6 and H.sub.2S with the timing sequence (MoF.sub.6—N.sub.2—H.sub.2S—N.sub.2)=(1-10-1-10 s) and MoS.sub.2 ALE was performed using MoF.sub.6 and H.sub.2O.

(18) FIG. 17 shows the mass change over cycle time in relation to the deposition of Al.sub.2O.sub.3 and MoS.sub.2.

(19) FIG. 18A shows FTIR difference scans of the last Al.sub.2O.sub.3 cycle at the bottom and the first two cycles of MoF.sub.6 and H.sub.2S. FIG. 18B shows each half cycle of MoF.sub.6 and H.sub.2S on top of HfO.sub.2, showing the background increase of the background absorption due to the increase in free carriers in the film.

(20) FIG. 19A shows FTIR difference scans of the last HfO.sub.2 cycle at the bottom and the first two cycles of MoF.sub.6 and H.sub.2S. FIG. 19B shows each half cycle of MoF.sub.6 and H.sub.2S on top of HfO.sub.2, showing the background increase of the background absorption due to the increase in free carriers in the film.

(21) FIG. 20A shows FTIR difference scans of the last MgO cycle at the bottom and the first two cycles of MoF.sub.6 and H.sub.2S. FIG. 20B shows each half cycle of MoF.sub.6 and H.sub.2S on top of HfO.sub.2, showing the background increase of the background absorption due to the increase in free carriers in the film.

(22) FIG. 21 shows impact of precursor dosage and cycle time.

(23) Reference is made to the accompanying drawings throughout the following detailed description. In the drawings, similar symbols typically identify similar components, unless context dictates otherwise. The illustrative implementations described in the detailed description, drawings, and claims are not meant to be limiting. Other implementations may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented here. It will be readily understood that the aspects of the present disclosure, as generally described herein, and illustrated in the figures, can be arranged, substituted, combined, and designed in a wide variety of different configurations, all of which are explicitly contemplated and made part of this disclosure.

DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS

(24) Embodiments described herein relate generally to formation of TMDs by ALD. ALD offers the best combination of a layer-by-layer growth of the material with highest conformality and integration with other oxides such as high-K dielectrics (e.g., Al.sub.2O.sub.3, HfO.sub.2, etc.) to realize 3D heterojunctions. The ability to control the synthesis of films over large areas will be important for future large-scale manufacturing for integrating into complex device structures.

(25) ALD is a vapor-phase, thin film deposition method based on alternating self-limiting surface reactions. ALD typically uses gaseous precursors to react with the exposed surface (of a substrate, then of preceding layers). The precursors are selected such that the first precursor binds to the substrate and then is modified by reaction with the second precursor to leave the desired element or compound. The precursor may be applied as a continuous exposure for a period of time or may be applied as micropulses of very short duration extending over a period of time. A purge gas may be used to clear the reaction chamber of a precursor, both to ensure termination of the reaction and prevent undesired reactions with the other precursor is injected. The nature of ALD lends itself to be a unique deposition method capable of precise control over thin film thickness and stoichiometry, as well as the ability to deposit conformal coatings over high surface area morphologies.

(26) TMD can be represented as MX.sub.2 where M is a transition metal and X is a chalcogenide. TMDs have a layered structure where each layer consists of an X-M-X unit. TMD crystals are typically described as having trigonal or octahedral prismatic coordination to help describe the material in a single layer, where each M atom has six X atoms forming a hexagon above and below it. These atomic trilayers feature strong in-plane covalent bonding but weak van der Waals bonding between layers. This dichotomy of bonding characteristics facilitates the synthesis and isolation of single layer TMDs. MoS.sub.2 in the bulk crystalline form has three stable phases under standard conditions: 2H, 3R and 1T.

(27) One embodiment relates to a method of forming TMDs on a substrate via ALD by performing a atomic layer deposition exposures of a transition metal precursor at a first deposition temperature between 100° C. and 300° C. and b) atomic layer deposition exposures of a sulfur precursor at a second deposition temperature between 50° C. and 300° C., and forming a transition metal dichalcogenide coating on the substrate. It should be appreciated that the ALD TMD growth, as well as optimal temperature, will vary based on the precursor sublimation temperature and the stability. Deposition temperature is based on thermodynamics of the precursors reaction at elevated temperature. In one embodiment, the temperature for deposition is between 100° C. and 400° C. In one embodiment, the growth temperature range for the ALD process is 50° C.-300° C.

(28) The a and b exposures constitute one ALD cycle. The TMD film can be made thicker by performing additional ALD cycles. The resultant deposited material may be further processed by annealing. In one embodiment the annealing temperature range for the ALD process is 400° C.-800° C.

(29) ALD cycle duration will be based on precursor vapor pressure and its subsequent saturation behavior and the depositing object surface area. For example, in one embodiment using a 300 mm Si wafer substrate, one ALD cycle duration can be (MoF.sub.6—N.sub.2—H.sub.2S—N.sub.2)=(1-10-1-10 s). However, using porous glass (8″×8″) as a substrate with surface area ˜10 m.sup.2, one ALD cycle duration can be (MoF.sub.6—N.sub.2—H.sub.2S—N.sub.2)=(10-30-10-30 s). FIG. 21 illustrates that deposition cycles for the first precursor and second precursor can be used in many combinations given below but number of doses and time will be based on precursor saturation on the surface.

(30) The general recipe for ALD will be based on many factors known to those skilled in the art, such as the nature of ALD cycles, precursor functional group, vapor pressure, substrate temperature, reactor geometry, ALD reaction chamber pressure, and, most importantly, the combination of precursors. CVD-type precursors may not be compatible due to the difference in the processes. For example, MoS.sub.2 using MoF.sub.6—H.sub.2S by ALD is feasible but MoS.sub.2 using (Mo(CO.sub.5)—H.sub.2S is not feasible by ALD (but could be for CVD).

(31) For example, ALD MoS.sub.2 can grow at 100° C. using MoF.sub.6—H.sub.2S. In a second example, ALD HfS.sub.2 can grow at 150° C. with TDMA-Hf and H.sub.2S. HfS.sub.2 can also be prepared at >200° C. with HfCl.sub.4 and H.sub.2S. In the HfCl.sub.4 precursor case, the sublimation temperature for HfCl.sub.4 is 150° C.; therefore, the deposition temperature must be higher to avoid condensation of the HfCl.sub.4.

(32) Mixed TMDs can be prepared by alternating between the ALD chemistries of the component materials. For instance, mixed MoS.sub.2—HfS.sub.2 can be prepared by performing c MoS.sub.2 ALD cycles followed by d HfS.sub.2 cycles. The composition of the film is dictated by the c/d ratio, while the thickness is determined by the total cycle number c+d.

(33) Doped TMDs can be prepared by interposing one or more cycles of a second TMD material during the process of growing a first TMD material. For instance, Mg-doped HfS.sub.2 can be prepared by interrupting the ALD chemistry for HfS.sub.2 (TDMA-Hf/H.sub.2S) and performing one or more cycles of Mg(Cp).sub.2/H.sub.2S, and then returning to the HfS.sub.2 chemistry. The doping level of Mg is controlled by the ratio of MgS.sub.2 cycles to the total number of TMD cycles, and the thickness is determined by the total number of ALD TMD cycles.

(34) Doping of the TMD can tune the bandgap and other properties. For example, MoS.sub.2 can be doped with W using tungsten hexafluoride (WF.sub.6) to form a compound described as WxMoyS.sub.2. In one embodiment, the doping is accomplished by selection of a compatible precursor (e.g., MoF.sub.6 and H.sub.2S for MoS.sub.2 growth and WF.sub.6 for dopant, and vice versa), which can give good material and only F can be impurity. The dopant precursor may be selected such that the waste material after ALD reaction includes the same elements or materials as for the primary ALD reaction (MoS.sub.2 formation, in one example). In other cases, one can deposit MoS.sub.2 using MoF.sub.6 and H.sub.2S and then dope W with other precursor (e.g., W(CO).sub.5); in that case, W-doped MoS.sub.2 material can deposit but now we may have F and C as impurity.

(35) In particular, described herein are two examples of TMDs deposited by ALD: MoS.sub.2 ALD using MoF.sub.6 and H.sub.2S and HfS.sub.2 using Hf(TMAH).sub.4 and H.sub.2S. Notably, while CVD processes have used a wired range of precursors, such cannot be expected to simply be usable directly in ALD. As those in the art will appreciate, CVD relies upon a reaction of two precursors in their gaseous or vapor form with the resultant material deposited on the surface of the underlying substrate. In contrast, ALD proceeds via the saturated surface reactions of first one precursor and then the other.

(36) MoF.sub.6 is reduced readily by both Si and H.sub.2:
2MoF.sub.6(g)+3Si(s).fwdarw.2Mo(s)+3SiF.sub.4(g)  (1)
MoF.sub.6(g)+3H.sub.2(g).fwdarw.Mo(s)+6HF(g)  (2)
The free energy changes for these reactions are −450 and −237 kJ/mol Mo, respectively, at 200° C., indicating that both reactions are thermodynamically highly favorable. In a previous report of Mo layers by ALD using MoF.sub.6 and disilane, the authors reported self-limiting behavior but measured a higher than predicted growth per cycle which they attributed to CVD (i.e., MoF.sub.6.fwdarw.Mo+3F.sub.2) promoted by local, transient heating from the very exothermic ALD surface reactions.

(37) In, examples described below, x-ray amorphous molybdenum sulfide films were grown by ALD using MoF.sub.6 and H.sub.2S. In situ QCM measurements revealed that both half-reactions are self-limiting at 200° C. Crystalline films were achieved after annealing at 350° C. in a hydrogen environment. The growth rate could be enhanced using diethyl zinc without changing the optical band gap of the material.

EXAMPLES

(38) ALD of MoS.sub.2

(39) In one experimental embodiment, a MoS.sub.2 coating was fabricated using the parameters listed in Table 1 below.

(40) TABLE-US-00001 TABLE 1 Parameters Values Precursor MoF.sub.6 and H.sub.2S Number of ALD cycles up to 1000 ALD cycles duration (MoF.sub.6—N.sub.2—H.sub.2S—N.sub.2) Optimized (1-5-1-5 s) Deposition temperature 200° C. Purge gas (N.sub.2) flow 300 sccm Thermal annealing (1Torr H.sub.2) 350° C.

(41) MoS.sub.2 ALD was performed using a custom viscous flow, hot-walled reactor, which was detailed previously. Deposition was performed on ˜1″×1″ coupons of Si with the native oxide intact and fused silica. The reactor temperature was maintained at 200° C. for all samples. During growth, ultra-high purity N.sub.2 (99.999%) was adjusted so the system process pressure was approximately 1 Torr. Molybdenum hexafluoride (MoF.sub.6 98%, Sigma Aldrich) and hydrogen disulfide (H.sub.2S 99.5%, Matheson Trigas) were sequentially pulsed into the reactor with purges of N.sub.2 between each exposure. The MoF.sub.6 and H.sub.2S partial pressures were 20 mTorr and 150 mTorr during dosing of the respective precursor. The delivery pressure in the reactor for both precursors was regulated with both an inline 200 μm aperture (Lenox Laser) and a metering valve. Both gases are extremely dangerous and special precautions are needed due to the flammability/toxicity of H.sub.2S and the corrosive nature of MoF.sub.6. The ALD timing can be described as t.sub.1-t.sub.2-t.sub.3-t.sub.4, where t.sub.1 and t.sub.3 are the MoF.sub.6 and H.sub.2S exposure times, respectively, and t.sub.2 and t.sub.4 are the corresponding purge times, with all times in seconds (s). For the MoS.sub.2 growth, t.sub.1 and t.sub.3 were both 1 s, while the purge times (t.sub.2 and t.sub.4) were kept at 5 s. In some experiments, the samples were annealed in situ after deposition on a temperature-controlled hot stage. The sample annealing was performed in ultrahigh purity hydrogen at 350° C. holding for 15 min. The samples were then cooled quickly back to room temperature. In addition to the binary chemistry of MoF.sub.6 and H.sub.2S, the MoS.sub.2 ALD was promoted/doped with ZnS using two successive ZnS ALD cycles composed of DEZ (99% Sigma Aldrich) and H.sub.2S.

(42) Experiments deposited MoS.sub.2 on variety of substrates, such as Silicon, SiO.sub.2, polyamide, quartz, anodic aluminum oxide (AAO), trench wafer, ITO, W, Mo, TiN, etc. This ALD grown MoS.sub.2 layers was characterized by various method and confirms the desire material growth.

(43) The MoS.sub.2 ALD was investigated by in situ QCM measurements using a modified Maxtek Model BSH-150 sensor head. An RC-cut quartz crystal (Phillip Technologies) with an alloy coating was used as the sensor due to its broad temperature range. To prevent deposition on the back side of the crystal, silver paste was used to seal the crystal and sensor head. A backside N.sub.2 purge was adjusted to approximately 0.5% of the process pressure.

(44) XPS measurements were carried out at the KECKII/NUANCE facility at Northwestern University on a Thermo Scientific ESCALAB 250 Xi (Al Kα radiation, hv=S5 1486.6 eV) equipped with an electron flood gun. Lower resolution survey scans and high resolution scans of the 3d, 2s, and 2p electron energies were performed. The XPS data were analyzed using THERMO ADVANTAGE 5.97 software, and all spectra were referenced to the C1s peak (284.8 eV). Peak deconvolution in the high-resolution spectra (Mo 3d, S 2p) was performed using the Powell fitting algorithm with 30% mixed Gaussian-Lorentzian fitted peaks in all cases. Fitting procedures were based on constraining the spinorbit split doublet peak areas and FWHM according to the relevant core level (e.g., 3d.sub.5/2 and 3d.sub.3/2 is constrained to 3:2 peak area).

(45) Raman spectroscopy (inVia, Renishaw) was used to probe the layered structure. The E.sub.2g and A.sub.1g vibrational modes arise from the in-plane and out-of-plane modes, respectively. Measurements were performed in reflection using an excitation wavelength of 514 nm on all samples. To prevent sample damage, a neutral density filter of 5%-10% transmission was used. A D2 Phaser x-ray diffractometer (XRD) (Bruker) using a Cu Kα source in Bragg-Brentano geometry was used to probe the crystallinity and crystal structure of the MoS.sub.2. A J. A. Woollam, Inc. α-SE Ellipsometer (Lincoln, Nebr.) was used to measure the thickness of the bulk films using a Cauchy model.

(46) The optical properties of the ALD molybdenum sulfide were measured using a Cary 5000 spectrophotometer (Varian) in transmission mode on films deposited on fused silica substrates. Kapton tape was placed on the backside of the quartz substrates during ALD and removed prior to measurement to mask off the region probed by the Cary 5000 beam. Prior to each measurement, a background reference was recorded to ensure accuracy. Linear regression of Tauc-plots was used to determine the optical band-gap of the films.

(47) Thermodynamic calculations (HSC Chemistry, Outotec Oy) of the Gibbs free energies of reaction (ΔG) were performed to evaluate possible chemical reactions occurring during the molybdenum sulfide ALD. Two plausible chemical pathways were identified: direct and indirect. In the direct pathway, MoF.sub.6 and H.sub.2S react to form MoS.sub.2, HF, and elemental S (Eq. (3)), with ΔG=−379 kJ/mol at 200° C. In the indirect pathway, the initial solid-phase product is MoS.sub.3 (Eq. (4)), with ΔG=−402 kJ/mol at 200° C. Subsequent H.sub.2 reduction (Eq. (5)) yields MoS.sub.2, with ΔG=−24 kJ/mol at 350° C. We compute ΔG at 350° C. for Eq. (5) to match the experimental conditions used in the postdeposition annealing. We note that the indirect pathway has a greater thermodynamic driving force (ΔG=−426 kJ/mol) compared to the direct pathway (ΔG=−379 kJ/mol). Moreover, the direct pathway might have a larger activation energy given the requirement for Mo reduction (+6 to +4) in Eq. (3), and so the indirect pathway might be kinetically favored as well. These mechanistic considerations will come into play later in our data analysis.
MoF.sub.6(g)+3H.sub.2S(s).fwdarw.MoS.sub.2(s)+6HF(g)+S(s)  (3)
MoF.sub.6(g)+3H.sub.2S(s).fwdarw.MoS.sub.3(s)+6HF(g)  (4)
MoS.sub.3(s)+H.sub.2(g).fwdarw.MoS.sub.2(s)+H.sub.2S(g)  (5)

(48) Initial QCM studies were performed to probe the degree of self-limitation for the MoF.sub.6 and H.sub.2S half-reactions. FIG. 1A shows the in situ QCM measurements (red circles) recorded using the timing sequence x-5-1-5, where the MoF.sub.6 exposure time was varied between x=0-2 s. The growth per cycle values were calculated assuming a bulk density of MoS.sub.2, d=5.06 g/cm.sup.3. The QCM data were fit with a Langmuir adsorption curve (line) and demonstrate saturation after ˜1 s MoF.sub.6 exposure time at 0.4 Å/cycle. These measurements were repeated using the timing sequence 1-5-x-5, where the H.sub.2S exposure time was varied between x=0-2 s and revealed saturation after ˜1 s H.sub.2S exposures at 0.40 Å/cycle (FIG. 1B). The data from FIGS. 1A-1B confirms the systematic self-limiting growth of MoS.sub.2 during both MoF.sub.6 and H.sub.2S doses, which is typical signature of good ALD method.

(49) FIGS. 2A-2B show the in situ QCM measurements during molybdenum sulfide ALD at 200° C. using the timing sequence 1.5-15-1.5-15 s. FIG. 2A shows a longer term view of over 19 ALD cycles. A steady growth rate associated with each cycle is seen. FIG. 2B illustrates an expanded view of two successive ALD cycles, allowing for a clearer image of the growth rate and timing relative to the pulses for each cycle. The MoF.sub.6 and H.sub.2S dosing periods are indicated by the respective traces at the bottom of the graph. We found linear growth at a GPC of 0.46(±0.01) Å/cycle using d=5.06 g/cm.sup.3. This value is slightly higher than the GPC value of 0.40 Å/cycle from FIGS. 1A-1B and this discrepancy may relate to the longer dose times of 1.5 s used for both precursors in FIG. 2A, while in FIG. 1A one of the precursor dose times was fixed at 1.0 s. The data from FIGS. 1A-1B confirms the systematic mass addition due to the deposited material and linear growth of MoS.sub.2 as a function of number of ALD cycles (time).

(50) The data in FIG. 2A show a regular staircase pattern that coincides with the precursor dosing times. FIG. 2B shows a magnified view of the QCM data for the first two ALD cycles. We see that the thickness (or mass) increases abruptly during the MoF.sub.6 exposures and decreases abruptly during the H.sub.2S exposures. Furthermore, the mass decreases continuously during the MoF.sub.6 purge periods and appears to approach a steady-state value. In contrast, the mass is constant during the H.sub.2S purge times. The slight delay between the QCM response and the precursor dosing traces results from the transit time of ˜0.5 s required for the precursors to travel from the dosing valves to the QCM in our ALD system.

(51) The relative mass changes produced by the MoF.sub.6 and H.sub.2S exposures can be used to evaluate the molybdenum sulfide growth mechanism. If we assume that the molybdenum sulfide ALD proceeds via the direct route (Eq. (3)) and, furthermore, that the sulfur product sublimes from the surface, then we can propose the following surface reactions:
(SH)*.sub.x+MoF.sub.6(g).fwdarw.(S).sub.xMoF*.sub.(6-x)+xHF(g)  (6)
(S).sub.xMoF*.sub.(6-x)+3H.sub.2S(g).fwdarw.S.sub.2Mo(SH)*.sub.x+S(s)+(6−x)HF(g)  (7)
where surface species are designated with “*,” and all other species are in the gas phase. In Eq. (6), MoF.sub.6 reacts with x surface thiol (SH) groups liberating x HF molecules, so that (6−x) F atoms remain bound to the Mo. In Eq. (7), the new surface reacts with H.sub.2S to release the remaining (6−x) F atoms as HF and solid S. We hypothesize sulfur subsequently becomes a volatile species, probably in the form of S.sub.8, while the surface has the newly formed MoS.sub.2 species and is terminated with x SH groups so that the original surface functionality is restored. We note that the hypothesis of S sublimation is reasonable given that the vapor pressure of S is ˜2 Torr at 200° C. We can define the QCM step ratio as R=Δm.sub.A/Δm, where Δm.sub.A is the mass change from reaction Eq. (6) and Δm is the mass change for one complete ALD cycle minus the sulfur species we assumed has entered the gas phase after the reaction. Given the atomic weights of the surface species, we can write
R=Δm.sub.A/Δm=(210−20x)/160  (8)

(52) The average step ratio from the QCM data in FIG. 2A is R=1.32(±0.05). From Eq. (8), this implies that x=0, meaning that there are no surface thiols involved in the ALD process, but rather the MoF.sub.6 reacts leaving all six F atoms on the surface (some of which may bond to other nearby Mo atoms).

(53) Alternatively, the molybdenum sulfide ALD may proceed via the indirect route (Eq. (4)), which suggests the following half-reactions:
(SH)*.sub.x+MoF.sub.6(g).fwdarw.(S).sub.xMoF*.sub.(6-x)+xHF(g)  (9)
(S).sub.xMoF*.sub.(6-x)+3H.sub.2S(g).fwdarw.S.sub.3Mo(SH)*.sub.x+(6−x)HF(g)  (10)
These reactions are identical to Eqs. (6) and (7), with the exception that all of the S remains on the surface and the ALD film has the composition MoS.sub.3. Eqs. (9) and (10) yield the following QCM mass ratio:
R=ΔM.sub.A/ΔM=(210−20x)/192  (11)

(54) Eq. (11) predicts R=1.09 for x=0, and R=0.47 for x=6. In other words, there is no x value that yields the experimental QCM step ratio R=1.32(±0.05), implying that the indirect pathway (Eq. (4)) is not correct. Given that the QCM data are consistent with the direct pathway (Eq. (3)), then a plausible interpretation for the gradual mass loss during the MoF.sub.6 purge time is the slow sublimation of S from the surface.

(55) Next, the growth rate and physical properties of the deposited TMD coating was investigated. FIGS. 3A-3B illustrate results of further experiments relating to embodiments of the deposited TMD. FIG. 3A shows film thickness as a function of MoS.sub.2 ALD cycles as measured by ellipsometry. FIG. 3B is an SEM image of an as-deposited film after 600 cycles with a thickness of 45 nm (left) and annealed film (right). The inset of FIG. 3B shows a higher resolution SEM image of the as-deposited film. ALD reaction carried out at 200° C.

(56) FIG. 4A shows Raman spectroscopy using a 514 nm excitation laser showing the as-deposited film (lower), which exhibits a MoS.sub.3 peak at 435 cm.sup.−1, and the annealed sample (upper) featuring clear MoS.sub.2 fundamental peaks. FIG. 4B shows X-ray diffraction pattern of the as-deposited and annealed sample. After annealing, the (002) reflection associated with the layered structure of MoS.sub.2 is seen. Both the Raman signal and X-ray diffraction peak position data confirms that as deposited layer is amorphous and the formation of high quality crystalline MoS.sub.2 layer after H.sub.2 annealing process.

(57) A series of films were deposited on silicon and fused silica substrates using the 1-5-1-5 timing sequence at 200° C., varying the number of ALD cycles between 100 and 1000. The thicknesses of the films deposited on silicon were determined using spectroscopic ellipsometry, and these data are shown as the solid symbols in FIG. 3A. The line in FIG. 3A is a quadratic fit to the thickness data and demonstrates that the thickness does not increase linearly with cycles as expected for a layer-by-layer ALD process. The thickness after 100 cycles is 60 Å, and the thickness after 1000 cycles is 750 Å, so that the corresponding growth per cycle values are 0.60 and 0.75 Å/cycle, respectively. Both of these values are significantly higher than the value derived from in situ QCM in FIG. 2A of 0.46 Å/cycle where only 19 cycles were performed. It is evident that the growth per cycle for the ALD MoS.sub.2 increases with thickness.

(58) One explanation for this phenomenon can be found in the SEM image for the 600 ALD cycle film on silicon shown in FIG. 3B. This plan-view SEM image shows a rough morphology composed of flakes with lateral dimensions of 50-100 nm and thicknesses of ˜10 nm. Additional SEM images recorded at an angle of 20° to the substrate normal (not shown) indicate that these flakes extend approximately vertically from the silicon substrate surface. We hypothesize that these flakes create a surface area that increases with increasing ALD cycles and this leads to greater MoS.sub.2 deposition. This unusual morphology might result from faster growth at the edges of the MoS.sub.2 sheets where the ALD precursors react with defect sites. Data from FIG. 3A confirms the growth of MoS.sub.2 is very linear as number of ALD cycles and microstructure is uniform over the substrate.

(59) Raman spectroscopy is a common method for identifying and characterizing MoS.sub.2. FIG. 4A shows Raman spectra recorded from the 600 ALD cycle MoS.sub.2 film on silicon using a 514 nm excitation laser as deposited (black line) and after the H.sub.2 anneal (red line). The annealed MoS.sub.2 film shows the characteristic peaks of the 2D material at 380 cm.sup.−1 (E.sub.2g, in-plane) and 410 cm.sup.−1 (A.sub.1g, out-of-plane). In contrast, the as-deposited film does not show these characteristic 2D MoS.sub.2 peaks but rather shows a weak peak at ˜435 cm.sup.−1. This suggests that the as-deposited films are not stoichiometric MoS.sub.2, or that they lack short-range order.

(60) Pre-annealed samples showed an amorphous film when measured by XRD; however, after annealing, MoS.sub.2 could be seen, featuring the (002) reflection, which arises from the layered structure. The XRD data from MoS.sub.2 are consistent with the Inorganic Crystal Structure Database PDF 01-073-1508 for the interplanar spacing.

(61) XPS measurements were performed on both the as deposited films and the films annealed in H.sub.2 to investigate the chemical composition. These films were prepared using 600 ALD cycles with a thickness of 45 nm. FIGS. 5A-5B show low-resolution survey scans for the as-deposited (FIG. 5A) and annealed (FIG. 5B) films. These spectra show that F, O, Mo, and S were present in the films and the relative concentrations are given in Table 2 below. The F detected by XPS likely results from unreacted MoF.sub.x species in the film. We believe that the O results from exposing the substrates to air. The MoS.sub.2 films were removed from the ALD reactor at 200° C., and oxidation of monolayer MoS.sub.2 has been shown to occur as low as 100° C. The concentrations of both the F and O decrease during the H.sub.2 anneal.

(62) High-resolution XPS data from the Mo 3d and S 2p regions before and after H.sub.2 anneal are shown in FIGS. 6A-6D. The energies of the Mo 3d and S 2p peaks were consistent with chemically exfoliated MoS.sub.2 samples. These spectra indicate that there exists MoS.sub.2 and substoichiometric (MoS.sub.x) environments due to the presence of an oxide phase after exposure of the samples to ambient air. The cause for the substoichiometric MoS.sub.2 (MoS.sub.x, where x<2) is associated with MoS.sub.2 dilution in an oxidized Mo (MoO.sub.x) phase, generating a possible mixed (Mo—O.sub.x—S.sub.x) molybdenum oxysulfide species. In fact, oxygen is known to have a high reactivity with the edge defects found in MoS.sub.2 nanoflakes, which are also found in the present work (FIG. 3B). Based on the overall composition of Mo and S (Table 1), the presence of a mixed Mo(IV) and Mo(V/VI) environment contributes to the small S/Mo ratios of 1.1 and 1.35 for the as-deposited and annealed samples, respectively. Again, this is not surprising given the strong precedence for the stability of MoO.sub.2 and MoO.sub.3 species at temperatures below 550° C. compared to MoS.sub.2, even when sulfurization is undertaken. After analysis of the high-resolution Mo 3d peak envelope (FIG. 6A), the integrated peak areas of the peaks corresponding to the spin-orbit split 3d.sub.5/2 and 3d.sub.3/2 contributions for MoS.sub.2 (˜228 and ˜231, respectively) relative to the neighboring S—Mo—O.sub.x/Mo—O.sub.x doublet (˜229 and ˜232 eV, respectively) in the as-deposited and annealed samples increased by 36% and 50%, respectively. Thus, the higher relative amount of MoS.sub.2 after annealing the films in H.sub.2 at 350° C. corroborates the appearance of the (002) diffraction peak in the XRD pattern (FIG. 4B), which is characteristic of layered MoS.sub.2. Examination of the high-resolution S 2p XPS peak envelope for both the as-deposited (FIG. 6C) and annealed samples (FIG. 6D) demonstrates the presence of only S.sup.2− with spin orbit split 2p.sub.1/2 and 2p.sub.3/2 contributions arising at 162.9 and 161.7 eV, respectively. It can be concluded that, in addition to removing residual F arising from the MoF.sub.6 precursor, the postannealing procedure was effective in removing some of the oxygen from the stable Mo—S.sub.x—O.sub.x phase, which yielded a purer distribution of MoS.sub.2 with more dominant contributions attributed to Mo(IV) in the Mo 3d XPS region.

(63) TABLE-US-00002 TABLE 2 Atomic percentages as determined by XPS. Sample Mo S F O As-deposited 34.03 37.61 4.37 16.2 Annealed 36.54 48.9 1.22 12.7

(64) To summarize, XRD suggests that the as-deposited film is amorphous whereas the SEM image shows what appear to be nanocrystals. It is likely that the diffraction peaks from these nanocrystals are too weak or broad to be detected by our XRD. The Raman measurements do not indicate crystalline MoS.sub.2 as-deposited, and this may result from the residual F detected in the films by XPS. Finally, XPS indicates predominantly Mo(IV), and this agrees with the in situ QCM measurements that suggested MoS.sub.2 is the reaction product.

(65) To measure the optical properties of the films, we used fused silica substrates that were masked with Kapton tape preventing deposition from occurring on one side. This process simplified the optical measurements since the beam was only interacting with a single film. FIG. 7A shows transmission data for ALD MoS.sub.2 films of 12, 32, and 60 nm thickness measured over the visible spectrum in specular transmission mode. FIG. 7B shows a fit to the 12 nm sample using a Tauc model assuming a direct, allowed transition, and the intercept of this line yields a band-gap of approximately 1.34 eV. This value agrees with literature values for bulk MoS.sub.2.

(66) Further, an average steady state growth rather was observed. FIG. 3A illustrates the growth rate as a function of the H.sub.2S dose time, while FIG. 3B illustrates the growth as a function of the MoF.sub.6 dose time. Both parameters resulted in a stead state growth rate of about 0.42 angstroms. As can be seen, the increase in growth rate leveled off for each precursor at a certain dosage time. This likely represents the saturation of the surface or at least the available binding/reaction sites.

(67) We have shown that when using MoF.sub.6 and H.sub.2S as ALD precursors, self-limiting growth of x-ray amorphous MoS.sub.2 is attainable. Two routes of growth were proposed: indirect (MoS.sub.3) and direct (MoS.sub.2). The MoS.sub.3 route is thermodynamically favorable; however, QCM measurement showed that the direct route was the most plausible route. Moreover, XPS data confirmed the as-deposited films were MoS.sub.2. While molybdenum oxide was present, this was attributed to air exposure of the samples upon removal from the reactor at elevated temperature. After hydrogen annealing, crystalline MoS.sub.2 x-ray peaks and Raman peaks were visible.

(68) Enhancement of MoS.sub.2 ALD Using ZnS

(69) As previously discussed, WS.sub.2 ALD using WF.sub.6 and H.sub.2S can be accelerated by periodically dosing DEZ and H.sub.2S to form a monolayer of ALD ZnS. To explore whether this same phenomenon occurs during MoS.sub.2 ALD using MoF.sub.6 and H.sub.2S, we performed in-situ QCM measurements. FIG. 8A shows the mass versus time recorded by in situ QCM using the timing sequence 1-10-2-10 for the MoS.sub.2 ALD and 1-10-2-10 for the ZnS ALD. In these experiments, two ZnS ALD cycles were performed followed by 20 MoS.sub.2 ALD cycles, and this pattern was repeated several times. As shown in FIG. 8A, each time the ZnS ALD is performed, the subsequent MoS.sub.2 ALD is enhanced for the next 5-6 cycles and then decreases back to a steady state GPC value of ˜0.4 Å/cycle. This behavior is believed to be for the same reasons as for WS.sub.2 ALD, and it is speculated that surface Zn might act as a catalyst to reduce the WF.sub.6 and form ZnF, which is converted back to ZnS by exposure to H.sub.2S.

(70) Additional details can be gained from FIG. 8B, which shows an expanded view of FIG. 8A between 9 and 13 cycles as a plot of thickness versus time. The first two ALD ZnS cycles deposit ˜2 Å/cycle as expected, but the very first MoS.sub.2 ALD cycle following the ZnS deposits essentially zero mass. The second and third MoS.sub.2 ALD cycles deposit 3.7 and 2.8 Å/cycle, respectively, which are seven to nine times higher than the steady-state value of 0.4 Å/cycle. Moreover, the step shape for these initial MoS.sub.2 ALD cycles are much different from the steady-state step shape shown in FIG. 2B, indicating different surface chemistry for the MoS.sub.2 ALD half-reactions on the ZnS surface. Previous studies of WS.sub.2 ALD found ZnF.sub.2 crystals in the WS.sub.2 coating and speculated that reduction of the WF.sub.6 by surface Zn might accelerate the WS.sub.2 ALD. However, this hypothesis fails to account for the first WS.sub.2 ALD cycle, which showed no growth. One explanation for the previous work and the present study is that the initial MoF.sub.6 exposure both adds and removes material from the surface such that the net mass change is nearly zero. For instance, the MoF.sub.6 might react with surface ZnS to yield a volatile sulfide-fluoride compound:
Zns+MoF.sub.6(g).fwdarw.ZnF.sub.2+MoSF.sub.4(g)+H.sub.2S  (12)

(71) This reaction produces only a 6 amu mass change. Although very little is known about MoSF.sub.4, the analogous reaction with ZnO to form ZnOF.sub.4 is thermodynamically favorable (−116 kJ/mol at 200° C.), and the ZnOF.sub.4 is highly volatile (>1000 Torr at 200° C.). This etching reaction would explain the ZnF.sub.2 residue in the previous papers. Additional in-situ measurements including quadrupole mass spectrometry to identify the gas phase products and Fourier transform infrared (FTIR) absorption spectroscopy to evaluate the surface functional groups directing the surface reactions would help to understand better the surface chemistry for the ZnS—MoS.sub.2 ALD.

(72) Similar to the WS.sub.2 accelerated growth on ZnS, DEZ substitution of MoF.sub.6 pulses accelerated the MoS.sub.2 growth. Our QCM measurements suggest that an etching reaction involving volatile MoSF.sub.4 species may occur and could explain earlier reports of ZnF.sub.2 residues in WS.sub.2. This work offers an alternative halogen-based process for carbon-free atomic layer deposition of MoS.sub.2 at relatively low temperatures.

(73) ALD of Other TMD Materials

(74) In a further experiments, other TMD materials were synthesized, such as MgS2 using Mg(Cp).sub.2 and H.sub.2S and HfS2 using Hf (TMAH)4 and H.sub.2S. The ALD experimental conditions are shown in Table 3. The precursor dose and purge times are understood by those skilled in the art to be equipment-specific, and the values below were selected because they provided self-limiting ALD on the ALD tool used for these measurements.

(75) TABLE-US-00003 TABLE 3 No. Parameters Values for MgS.sub.2 Values for HfS.sub.2 1 Precursor Mg(Cp).sub.2 and H.sub.2S Hf (TMAH)4 and H.sub.2S 2 ALD cycles Optimized Optimized duration (metal (1-5-1-5 s) (1-5-1-5 s) precursor —N.sub.2—H.sub.2S—N.sub.2) 3 Deposition 200° C. 200° C. temperature 4 Purge gas (N.sub.2) 300 sccm 300 sccm flow 5 Thermal annealing 350° C. (1Torr H.sub.2)

(76) FIG. 9A shows QCM data for HfO.sub.2—HfS.sub.2—HfO.sub.2 10 s purge times and a constant 1 s dose times for the other precursor in both cases at 200° C. FIG. 9B shows QCM data magnified few ALD cycles of HfO.sub.2—HfS.sub.2 interface from FIG. 5A. QCM data for HfO.sub.2—HfS.sub.2—HfO.sub.2 10 s purge times and a constant 1 s dose times for the other precursor in both cases. From FIGS. 9A-9B, a linear steady state growth of HfS.sub.2 was achieved. Further, it is clear that there is immediate growth of HfS.sub.2 on HfO.sub.2 and vice versa. The mass deposited per HfS.sub.2 cycle=46 ng/cycle, whereas mass deposited per HfO.sub.2 ALD cycle 58 ng/cycle. The immediate growth of HfS.sub.2 on HfO.sub.2 and vice versa can produce very clean interface, which needed and desired for semiconductor devices.

(77) FIG. 10A shows QCM data for MgS.sub.2 10 s purge times and a constant 2 s dose times for MgCp.sub.2 and 0.5 s for H.sub.2S precursors at 200° C. FIG. 10B shows QCM data magnified few ALD cycles from FIG. 10A. QCM data for MgS.sub.2 10 s purge times and a constant 2 s dose times for MgCp.sub.2 and 0.5 s for H.sub.2S precursors. From FIGS. 10A-10B, a linear steady state growth of MgS.sub.2 was achieved. The mass deposited per HfS.sub.2 cycle=36 ng/cycle.

(78) The similar ALD growth methodology can be apply to the other layer structure materials using transition metals (Mo, W, Cr, Hf, Zr, Co, Pt, V, Ti, Ta, Nb, or Lathanides elements and a chalcogen (S, Se, Te)). For example, one precursor for Mo is MoF.sub.6 and one precursor for Hf is halfnium etrakis(dimethylamido)hafnium(IV). Thus, although different precursors may be used, the common aspect for the precursors is chalcogen precursor S. It is believed that having common chalcogen-rich surface for subsequent chemistry will help the next layer of material to grow, preferably with the with least nucleation delay.

(79) The metal precursors can be halides, amides, cyclopentadienyl (Cp) compounds, substituted Cp compounds, alkyls, carbonyls, alkoxydes, or heteroleptic compounds containing mixtures of these various ligands. The chalcogenide can be a hydride, amide, tris-methyl silyl amide, alkyl, or a mixture of these ligands.

(80) Compatible Deposition of Mo and MoS.sub.2

(81) Another concern for suitable TMD material on large-scale device integration is a suitable metal contact to the TMD layer. This issue can be deal with using metal Mo deposition on MoS.sub.2 layer with clean interface. To demonstrate this, we have used ALD Mo and ALD MoS.sub.2 on top of each other. The ALD experimental parameters are given in table below. It is understood by those skilled in the art that the ALD timings are instrument specific, the number of ALD cycles can be varied to suit the application, and the temperature for the metal can be varied within the ALD window for the Mo ALD. The range of MoS.sub.2 temperatures is given above.

(82) In one embodiment, ALD of Mo and ALD MoS.sub.2 are process compatible due to use of same the same precursor for both growing metallic Mo and MoS.sub.2, for example MoF.sub.6. In addition, deposition temperature can be same or different for MoS.sub.2 and Mo growth. Table 4 shows one set of parameters for the example embodiments of MoS.sub.2 deposited and then coated with Mo by ALD:

(83) TABLE-US-00004 TABLE 4 No. Parameters Values for Mo Values for MoS.sub.2 1 Precursor MoF.sub.6 and Si.sub.2H.sub.6 MoF.sub.6 and H.sub.2S 2 ALD cycles duration (MoF.sub.6—N.sub.2—Si.sub.2H.sub.6—N.sub.2) (MoF.sub.6—N.sub.2—H.sub.2S—N.sub.2) Optimized (1-5-1-5 s) Optimized (1-5-1-5 s) 3 Deposition temperature 200° C. 200° C. 4 Purge gas (N.sub.2) flow 300 sccm 300 sccm 5 Thermal annealing (1Torr H.sub.2) Optional (350° C.)

(84) QCM data was gathered for the resultant component. As seen in FIG. 11A, QCM data for MoS.sub.2—Mo—MoS.sub.2 layers show stack grown with 10 s purge times and 1 s dose times for the all MoF.sub.6, Si.sub.2H.sub.6, H.sub.2S precursors at 200° C. FIG. 11B shows QCM data for MoS.sub.2—Mo layers stack section zoom in from FIG. 11A. FIG. 11C shows QCM data for Mo—MoS.sub.2 layers stack section zoom in from FIG. 11A.

(85) It is clear that from FIGS. 11A-11C that both Mo and MoS.sub.2 can grow very immediately on top of each other with barely any nucleation delay. This process can able to produce clean interface between the MoS.sub.2 and Mo contact layer. This process is also simplified because there are no additional elements involved in the process. Overall, this type proposed approach ALD methodology could produce efficient clean metal-metal sulfide stack in economical manner (e.g., in addition to this same ALD growth chamber can be used to deposit both metal Mo and MoS.sub.2).

(86) Etching of MoS.sub.2

(87) Precisely controlled removal of thin film layers is very essential for next generation high density 3D devices fabrication. There are several ways one can perform the etching the materials. For example: A layer-by-layer etching [Atomic Layer Etching (ALEt), very precise but slow] Chemical vapor etching (CVE) [aggressive but, if controlled, fast and economical] Layer(s)-by-layer(s) etching [moderate etch rate and fast, as well as economical]

(88) As 2D-layered TMD materials are advantageous for next generation microelectronics and to integrate TMDs into 3D devices on larger scale, it is important to have both 3D conformal growth and etch process capabilities. For example, ALD is suitable for growing precisely and highly conformally materials on high aspect ratio 3D structures, whereas a well-controlled ALEt is very much suitable for etching (removing) material conformally and precisely from the 3D structure.

(89) Therefore, next we demonstrated the ALEt of MoS.sub.2 which is unique way of etching the MoS.sub.2. The developed method is very economical, well controlled, and can etch MoS.sub.2 in atomic layer-by-layer removal manner. Further, the ALEt recipe that we have used here is based on the MoF.sub.6—H.sub.2O process. This means we can grow ALD MoS.sub.2 using MoF.sub.6 and H.sub.2S (as discussed earlier in FIGS. 1-4) in same material processing chamber we can perform ALEt MoS.sub.2. This will reduce the cost of ownership not only having same material processing reactor but also the in terms of time and no need separate tool.

(90) FIG. 12 shows atomic layer etching reference from Journal of Vacuum Science & Technology A: Vacuum, Surfaces, and Films 33, 020802 (2015). The overall idea of using ALEt method is to remove the desire material in well controlled and precisely as well as conformal from 3D structure. For next generation 3D devices, this is needed because conventional reactive ion etching is very much directional and line-of-sight process, which may not suitable for removing material from 3D sites.

(91) FIG. 13 shows QCM data for only MoF.sub.6 dose pulses (2 s) followed by (20 s) purge on substrate at 200° C. The pulsing of MoF.sub.6 precursor only on substrate the ˜45 ng/dose. This is due to MoF.sub.6 precursor has thermal decomposition factor which resulted in mass add on substrate.

(92) FIG. 14 shows QCM data for MoF.sub.6—H.sub.2O dosing with cycle of (15-20-5-20)s on substrate at 200° C. The pulsing of MoF.sub.6—H.sub.2O precursors did not give any reasonable mass add on QCM substrate. In this case, to our best knowledge both volatile HF and MoF.sub.xOy reaction product is forming there for there is no major mass deposition on the QCM substrate.

(93) FIGS. 15A-15B show QCM for ALEt at 200° C. of ALD grown MoS.sub.2 (FIG. 15A) both MoF.sub.6 and H.sub.2O precursor microdosing (FIG. 15B) etching saturation as a function of both MoF.sub.6 and H.sub.2O dose time. For both precursors purge time kept constant (20 s). Prior to etching ALD MoS.sub.2 performed with MoF.sub.6 and H.sub.2S were pulsed using ALD cycle of (MoF.sub.6—N.sub.2—H.sub.2S—N.sub.2)=(1-10-1-10)s timing sequence until steady state growth was achieved at 200 C. The data from FIGS. 15A-15B confirms the systematic self-limiting etching of MoS.sub.2 during both MoF.sub.6 and H.sub.2O doses, which is typical signature of ALEt method.

(94) FIG. 16 shows QCM for ALEt at 200° C. of ALD grown MoS.sub.2 using MoF.sub.6—H.sub.2O precursor's chemistry. Prior to etching, ALD MoS.sub.2 performed with MoF.sub.6 and H.sub.2S were pulsed using ALD cycle of (MoF.sub.6—N.sub.2—H.sub.2S—N.sub.2)=(1-10-1-10 s) timing sequence until steady state growth was achieved at 200° C. The data from FIG. 16 confirms that the ALEt method based on MoF.sub.6—H.sub.2O precrusors developed for MoS.sub.2 etching is reproducible.

(95) FTIR is an excellent surface sensitive technique to further investigate and monitor the growth of ALD films. Performing the technique in situ allows for the investigation of how the surface species changes after each ALD half cycle. Performing the same experiment as in FIG. 17 (growing an Al.sub.2O.sub.3 surface followed by MoS.sub.2), we can visualize the surface specie change plotted in FIG. 18A at 150, 200, and 250° C. To better visualize the changes in the surface chemistry the data is plotted as difference spectra, where each spectrum is subtracted from the previous. Peaks above the baseline represents the formation/addition of that surface species, while peaks below the baseline means a loss. The lowest two plots show the last TMA and H.sub.2O half cycles. The symmetrical nature of the plots suggest that the Al.sub.2O.sub.3 is growing in a steady state regime as previously reported in literature. The middle plots show the first cycle of MoF.sub.6 and H.sub.2S, represented by the blue and green lines, respectively. Features in the 3750-2800 cm.sup.−1 region are associated with OH groups and are clearly negative confirming the reaction with surface OH groups during the first pulse of MoF.sub.6. Lack of these on the second cycle (top spectra) indicated a change in surface chemistry, which corroborate our previously proposed thiol exchange growth mechanisms. While thiol vibrational modes can be visualized with FTIR, they are typically very weak and were not detected. We did observe an increase in the background absorption as the number of MoF.sub.6 and H.sub.2S cycles increased (FIG. 18B). This would be expected if the free carriers in the film increase, and suggest MoS.sub.2 is growing on top of the Al.sub.2O.sub.3.

(96) FIG. 19A shows FTIR difference spectra of the HfO.sub.2—MoS.sub.2 interface following previous growth algorithms. Similar to the Al.sub.2O.sub.3—MoS.sub.2 interface the OH consumption is observed during the first dose of MoF.sub.6. Unlike the growth on Al.sub.2O.sub.3, at low temperatures interactions between the HfO.sub.2 and MoF.sub.6/H.sub.2S continue, indicated by the continued loss peaks in the 3750-2500 cm.sup.−1 range. This indicates that MoS.sub.2 growth on high dielectrics is not only temperature dependent but highly depends on the substrate. Regardless of the complex interactions, again a baseline absorption was observed as the number of MoF.sub.6 and H.sub.2S cycles were repeated (FIG. 19B), indicating MoS.sub.2 formation.

(97) Finally, FIG. 20A shows FTIR difference spectra of the MgO—MoS.sub.2 interface following previous growth algorithms. Again the OH consumption is observed during the first dose of MoF.sub.6, while little change is observed during the second cycle, like the AlO—MoS.sub.2 interface. Unlike the other interfaces, an extremely large peak is observed at ˜1000 cm.sup.−1, which is most likely indicating of a metal oxyfluoride. The lack of the same large peak during the second cycle would suggest that this is only formed during the first cycle. Like the previous two experiments, the background absorption was observed in FIG. 20B.

DEFINITIONS

(98) As used herein, the singular forms “a”, “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, the term “a member” is intended to mean a single member or a combination of members, “a material” is intended to mean one or more materials, or a combination thereof.

(99) As used herein, the terms “about” and “approximately” generally mean plus or minus 10% of the stated value. For example, about 0.5 would include 0.45 and 0.55, about 10 would include 9 to 11, about 1000 would include 900 to 1100.

(100) It should be noted that the term “exemplary” as used herein to describe various embodiments is intended to indicate that such embodiments are possible examples, representations, and/or illustrations of possible embodiments (and such term is not intended to connote that such embodiments are necessarily extraordinary or superlative examples).

(101) The terms “coupled,” “connected,” and the like as used herein mean the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent) or moveable (e.g., removable or releasable). Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another.

(102) It is important to note that the construction and arrangement of the various exemplary embodiments are illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present invention.

(103) While this specification contains many specific implementation details, these should not be construed as limitations on the scope of any inventions or of what may be claimed, but rather as descriptions of features specific to particular implementations of particular inventions. Certain features described in this specification in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination.