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a
Seagate Technology LLC, Recording Heads, One Disc Drive, NRE304, Bloomington, MN 55435, USA
b
Department of Materials, University of Oxford, Parks Road, Oxford OX1 3PH, UK
Received 15 December 2003; received in revised form 11 March 2004; accepted 13 March 2004
Available online 22 April 2004
Abstract
The development of nanoscale magnetic materials for applications in information storage systems relies heavily on the ability to
engineer the properties of the layered structures from which such materials are fabricated. These properties are strongly dependent
on the nature of the interfaces between the individual nanoscale magnetic layers, so knowledge of the interface chemistry is crucial.
In this paper, we discuss the application of three-dimensional atom probe analysis to the characterisation of layered magnetic
materials, including details of specimen preparation techniques required for this type of analysis. Recent results are presented on the
characterisation of interfaces in Co/Cu or CoFe/Cu multilayers, which form part of the read sensor in magnetic recording heads, and
Co/Pd multilayers, which are being considered for use as perpendicular recording media.
Ó 2004 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved.
1359-6454/$30.00 Ó 2004 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved.
doi:10.1016/j.actamat.2004.03.015
2848 D.J. Larson et al.: Overview No. 138 / Acta Materialia 52 (2004) 2847–2862
determine the nature of each individual interface unless a dius of curvature of 10–100 nm. For most materials,
technique is used that allows independent interface these sharp needles can be produced by electrochemi-
analysis with high spatial resolution. Low-angle X-ray cally polishing fine wires, whiskers or blanks cut from
diffraction (X-ray reflectivity) has been widely used to bulk material [12–16]. However, preparing a specimen
study layered thin film materials (see for example [8]). from certain sample geometries can be quite compli-
However, the X-ray reflectivity profiles that are obtained cated. Examples include certain multi-phase alloys,
are summed data that include contributions from all the semiconductors, ceramics and, in particular, thin film
interfaces in the structure. It can therefore prove ex- materials. Over the years, various methods have been
tremely difficult to obtain a unique fit to the data for applied to 3DAP specimen preparation in order to
multilayer films if the interfaces between different layers overcome these problems [13,14].
do not contain the same degree of roughness and/or This paper gives an overview of the results of recent
interdiffusion through the multilayer stack. Neutron 3DAP studies, both from our group and from other
reflectivity has also been applied to the study of inter- groups, of magnetic layered film structures (e.g. Ni/Cu,
faces in epitaxial superlattice structures and to poly- Co/Cu, CoFe/Cu, Co/Pd, etc.), concentrating on mate-
crystalline sputtered films but this technique is not as rials with potential applications in information storage
good at determining structural information as X-ray systems. These materials science studies have been made
reflectivity, and is therefore more usually applied using possible by recent progress in the application of high
polarised neutrons to determine magnetic structure (see resolution focused ion beam systems to the preparation
[9] for a recent review). of 3DAP specimens from complex layered systems, and
One of the most commonly used techniques that can this is also reviewed briefly.
be used to analyse each interface independently is
transmission electron microscopy (TEM) of cross-sec-
tion samples, which can be used to study both the mi- 2. Development of 3DAP specimens from thin film
crostructure and compositional profile across the layers samples
[10]. However, a limitation of TEM is that it is a pro-
jection technique and integration through the specimen In order to investigate thin layered structures in the
thickness can make it difficult to distinguish interfacial atom probe, these features must be present in the apex
mixing and fine-scale roughness except under very spe- region of the specimen. The preparation of 3DAP
cific conditions. An example is given by Hytch of sep- specimens from thin film structures is difficult, but is a
arating these two effects in Co/Cu multilayer films using crucial step in obtaining 3DAP data that provide the
detailed image analysis of through-focal series of Fresnel highest possible spatial resolution across the feature of
fringe images [11]. interest, in this case the interfaces in the layered struc-
The technique of three-dimensional atom probe ture. The specimen preparation process is difficult be-
(3DAP) analysis [12–15] is unique in having the capa- cause the total sample thickness (region of interest
bility to characterise internal interfaces, grain bound- containing the thin layers) is often only of the order of
aries and precipitates with sub-nanometre resolution in 20–100 nm. There are three main methods that have
all three dimensions. With this technique it is therefore been used to prepare 3DAP specimens from thin film
possible to measure the extent of interdiffusion or in- structures and these are outlined below.
terface segregation at the atomic scale, and separate A number of papers have been produced detailing the
these effects from nanometre-scale topological features. results of 3DAP studies carried out on thin film mate-
In a 3DAP, pulsed field evaporation is used to re- rials in which the films of interest were deposited directly
move individual atoms from the surface of a specimen, onto pre-evaporated needle-shaped specimens [17–30].
which is in the form of a needle with end radius 50 nm. Fig. 1(a) shows a schematic of the geometry of a speci-
A position-sensitive detector is used for measurement of men that has been prepared in this way, but note that
both flight time (to identify atomic species) and impact the curvature of the tip relative to the layer thickness is
position (which enables the original position of each not necessarily to scale (the tip radius is of the order of
atom on the specimen surface to be recorded). The po- 50 nm and the layer thickness is typically a few nano-
sition of an atom in the depth direction is calculated metres). The small volume from which the 3DAP data
from the sequence of ion detection. The 3DAP has a are taken (of the order of 20 nm in diameter) means that
depth resolution of a single atomic layer and sub- within the volume analysed the substrate approximates
nanometre lateral resolution. An intrinsic requirement to a flat surface, and the structure of the layers is often
of the 3DAP microscopy technique is the production of assumed to be reasonably similar to that of the same
a very high electric field (20–50 V/nm) at the surface of layers deposited on a planar substrate. However the
the specimen in order to achieve field evaporation. The microstructure is unlikely to be exactly the same, in part
field is produced by applying a high voltage (typically because the substrate material (in this case a metallic tip)
10 kV) to a needle-shaped specimen with an apex ra- does not correspond well to the substrates used in ap-
D.J. Larson et al.: Overview No. 138 / Acta Materialia 52 (2004) 2847–2862 2849
capability of the new generation of commercial high on post size but are typically of the order of 3 lm
resolution (<10 nm) focused ion beam (FIB) systems for (outer radius) and 1 lm (inner radius). The centre of
fabricating 3DAP specimens has only recently been the post is protected by the annular milling pattern
explored. during this stage of the milling process (typically 1 to 2
A modified version of the technique developed by min) and the result is shown in Fig. 3(b). The inner
Hasegawa, described above, has been used to enable radius of the annulus is then decreased (typically to
3DAP analysis to be carried out on 400 nm thick Co/Cu 0.4 lm) and further milling is carried out until the
multilayer films [45,46] deposited on a layer of photo- radius of the unmilled region of the specimen ap-
resist on a Si substrate. The dimensions of the pro- proximately matches the inner radius of the annular
truding portion of the sample are approximately pattern, Fig. 3(c). Fig. 4(a) shows the specimen ge-
3.0 0.4 150 lm, see Fig. 1(b). The protuding post ometry from the side at this point during the process
section of the sample was shaped using focused ion (the arrow shows the region of interest). Fig. 3(d)
beam milling with 10 keV gallium ions, to form a suit- shows a specimen after a final milling stage carried out
able 3DAP specimen [47,48]. A similar method has with reduced radii of the annulus (typically to 1 lm
subsequently been used as well by Schleiwies [49] to and 0.1 lm for the outer and inner radii, respectively)
prepare NiFe/Cu thin film specimens. The disadvantages and a reduced beam current (typically 10–30 pA) to
of this process are (1) that the films are deposited on a minimise Ga beam-induced damage. Figs. 4(b) and (c)
non-standard underlayer (photoresist); (2) that in the show low and high magnification images of the final
case of a layered film, the interfaces between the layers specimen shape. The radius is less than 100 nm and the
are oriented parallel to the axis of the specimen (see region of interest for 3DAP analysis is positioned at or
Fig. 1(b)) so that the resolution across the interfaces is near the apex of the needle.
reduced by lateral trajectory aberrations [13]; and 3) the
requirement for mechanical stability of the element
means that the fabricated layers must have a total
thickness of the order of 0.5 lm. Once this thickness is
reached, the microstructure increases in correlated
roughness and the magnetic properties may not be the
same as those of a very thin layered film (<10 nm thick),
such as would be of interest from a technological point
of view.
A third specimen preparation method (used in the
majority of the recent work by the current authors) uses
high aspect ratio, flat-topped Si posts as the substrate
for the 3DAP specimens [50]. This specimen orientation
enables the highest spatial resolution to be obtained
across the interfaces during analysis (see Fig. 1(c)). In
order to ensure transmission of the voltage pulses re-
quired for 3DAP analysis, low resistivity Si wafers
(0.01 X cm) are used. The wafers are patterned using
standard optical lithography followed by deep-trench
reactive ion etching (commonly referred to as the
‘‘Bosch’’ process [51]) to create posts having a very high
aspect ratio (up to 50 to 1) with an end size ranging
from 3 3 to 24 24 lm. Prior to metal deposition,
the native Si oxide on the surface is usually removed by
sputter etching in order to promote good adhesion of
the metal to the silicon. Single posts are removed from
the wafer and attached to a metallic needle using elec-
trically-conducting epoxy [52] as shown schematically in
Fig. 2(a). 3DAP specimens are then prepared from the
end of the post using 30 keV gallium ions with beam
currents of 30–1000 pA.
A brief overview of a typical specimen sharpening
Fig. 2. (a) Schematic diagram showing the use of electrically-con-
process [50] is shown in Figs. 2(b) (schematic), 3, and ducting epoxy to attach a silicon post to a metallic needle in prepa-
4. For the first milling step an annular milling pattern ration of focused ion beam milling, (b) schematic diagram of the
is used (shown in Fig. 3(a)) whose dimensions depend annular focused ion beam milling technique.
D.J. Larson et al.: Overview No. 138 / Acta Materialia 52 (2004) 2847–2862 2851
There are, of course, disadvantages associated with The FIB-damaged region can be removed and mon-
ion milling methods. For example, milling may intro- itored during 3DAP analysis. Alternatively, the dam-
duce implantation and defects into the near-surface aged region can be removed by DC field evaporation
region of the specimen but these can usually be re- while field ion imaging, or by low-energy ion sputtering
moved by field evaporation before atom probe analysis using field emission in the presence of Ne gas [53]. Note
proceeds. The FIB techniques described above lead to that only analyses that are relatively free of Ga im-
a region of the specimen that has been partially dam- plantation (less than 1–2% Ga) should be considered
aged by the Ga ion beam [48]. An example of the as representative of the original thin film microstructure.
problems associated with the use of a focused ion beam
for specimen fabrication using the modified Hasegawa
technique is shown in Fig. 5. No layers were visible in 3. Studies of layered thin films
the field ion image of a specimen containing a (Co2 nm /
Cu2 nm )100 multilayer film milled using the FIB at Over the last decade or so, the three-dimensional
10 keV [45]. Subsequent atom probe analysis showed atom probe technique has been applied to various lay-
the gallium content vs analysis depth to range from ered systems of interest for information storage mate-
6.5 at.% Ga initially to 0.5% Ga at a depth of 15 rials. These include Ni/Cu [21], Co/Cu [27,46], Ni/Al
nm, as seen in Fig. 5(a). For comparison, the results of [29], CoFe/Cu [54–56], NiFe/Cu [57], CoFe/NiFe [58],
analysis of a specimen fabricated using 30 keV gallium Fe/Cr [59], Co/Pd [60], as well as various magnetic ma-
ions are also shown. The gallium implantation level terial-based single film structures. The results of some of
was still 10–20% even up to a depth of 20 nm into these studies are discussed in more detail below.
the specimen. Fig. 5(b) shows atom maps of the Ga
and Cu taken from the 3DAP analysis of the specimen 3.1. Co/Cu and CoFe/Cu multilayer films
milled at 10 kV and whose Ga content is shown in
Fig. 5(a). The layered structure appears after 20 nm The modified Hasegawa technique was used by
of field evaporation, as shown by 3DAP (note that the current authors to prepare specimens from an
Fig. 5(b) does not include the first 10 nm of the profile Fe/(Cu2 nm /Co2 nm )100 multilayer film. An Fe seed layer
shown in Fig. 5(a)). was used in these samples to impart a strong (1 1 1)
Fig. 3. Silicon post (a) prior to pattern placement at low ion current (inset at high ion current), (b) the evolution of the end of the post as milling
proceeds using the 1 lm inner radius pattern, (c) the post after milling has reduced the radius of the unmilled region of the specimen to 0.4 lm and
(d) the post after milling at low current has reduced the radius of the unmilled region of the specimen to less than 0.1 lm.
2852 D.J. Larson et al.: Overview No. 138 / Acta Materialia 52 (2004) 2847–2862
Fig. 7. (a) 3DAP atom maps of Ni, Co and Cu atoms in the multilayer (volume is 20 nm 20 nm 35 nm), (b) selected-region composition
profile across two of the layers shown in (a).
the deposition rates (0.1 nm s1 ) and substrate tem- fact that the upper surface of the Cu layer is not con-
peratures (300–330 K) used here. The good agreement formal with the upper surface of the underlying CoFe –
between the simulated and experimental data shows that the deposition of the Cu has acted to smooth out the
3DAP analysis is really the first type of experiment that correlated roughness [54]. This smoothing effect had
can be used to check this model at the correct length been suggested by Eckl et al. [7] on the basis of in-situ
scale. A favourable comparison between model and resistivity measurements but was not confirmed by a
experiment also served to validate the MD simulation microstructural study.
parameters used for these materials and has encouraged The question then arises as to how the Cu grows in
both research groups to proceed with further compari- order to smooth out the roughness. Eckl et al. pro-
sons, as described below. posed that the initial Cu layer was deposited confor-
The data in Figs. 8 and 9 show a layered film in which mally on the underlying Co, followed by nucleation of
the top surface of the CoFe layer is relatively flat. islands of Cu in the troughs at the grain boundaries.
However growth of multilayer films with a strong [1 1 1] While the 3DAP data in Fig. 10 show the Cu
crystallographic texture often results in the top surface smoothing effect, the actual growth process cannot be
of the layers being rough, or wavy, with a period of a understood just from the 3DAP data as the technique
few nanometres. In many multilayer systems this peri- does not allow us to follow the process as a function
odicity is transferred through to subsequently deposited of time. However, this can be achieved using the same
layers, resulting in correlated roughness that usually MD simulation technique as discussed above [61].
becomes worse as more layers are deposited [8]. An Fig. 11 shows a series of images obtained during a
example of this is shown in Fig. 10. The roughness at the MD simulation of the growth of a Cu layer on a
top of the NiFe layer has been transferred up to the next rough CoFe layer [63]. Fig. 11(a) shows that the initial
CoFe layer, as can be seen from the isoconcentration monolayers of Cu are indeed deposited conformally
surface (surface of constant concentration of one or on the CoFe surface, as proposed by Eckl et al. The
more elements) shown in Fig. 10(a), plotted at a com- MD simulations indicate that as the Cu layer gets
position of 45 at% Co. A very interesting feature is the thicker, facets with (1 1 1) crystallographic planes
D.J. Larson et al.: Overview No. 138 / Acta Materialia 52 (2004) 2847–2862 2855
Table 1
Interface widths for CoFe/Cu MLFs for which the Cu layers were deposited either in Ar or in an Ar + oxygen mixture, for the as-deposited films and
for films annealed at 300 °C for 30 min
Cu deposition condition Interface widths (nm) Ave. Cumax Conc. (%)
CoFe-on-Cu Cu-on-CoFe
Ar – as-grown 1.21 (0.05) 0.49 (0.03) 65.1 13.3
Ar + O2 as-grown 0.55 (0.03) 0.31 (0.02) 77.1 11.72
Ar (300 °C/0.5 h) 1.16 (0.09) 0.61 (0.02) 72.1 7.6
Ar + O2 (300 °C/0.5 h) 3.01 (0.12) 2.38 (0.12) 55.6 7.4
2858 D.J. Larson et al.: Overview No. 138 / Acta Materialia 52 (2004) 2847–2862
%Co %Cu
100
Concentration (at%)
90
80
70
60
50
40
30
20
10
0
0 1 2 3 4 5 6 7 8
(a) Distance (nm)
70 Co% Cu%
60
Concentration (at%)
50
40
30
20
10
0
0 5 10 15 20 25 30 35
Fig. 15. Atom map from 3DAP data for the as-deposited CoFe/Cu
MLF deposited using Ar + oxygen. The oxygen atoms (large, spheres) (b) Distance (nm)
and Cu atoms (small, dark spheres) are shown. The presence of a
columnar grain boundary is indicated. (Reproduced from [55] with Fig. 16. Composition profiles (showing only Co and Cu) across CoFe/
permission from The American Physical Society.) Cu multilayer films following annealing at 300° C for 30 min (a) for
deposition of Cu layers in Ar, and (b) for deposition of Cu layers in
Ar + oxygen.
port properties can be accounted for by changes to the intermixing at the Cu–CoFe interfaces to occur during
microstructure that occur during annealing. Fig. 16 annealing. On the other hand intermixing in the layers
shows composition profiles taken from 3DAP analyses grown without oxygen appears limited to that which
across annealed CoFe/Cu multilayer films with the Cu occurs by atomic exchange during sputter deposition
layers deposited (a) in Ar and (b) in Ar + oxygen. As can [61]. However it is not clear from our results whether the
be seen from Table 1, the increase in interfacial mixing is intermixing has occurred by long-range changes in the
relatively small for the film deposited in Ar (the Cu interface position in order to establish the equilibrium
layers are still well defined), but for the film deposited in shape, or whether the non-equilibrium configuration
the presence of oxygen, the CoFe-on-Cu interface width raises the free energy of the system sufficiently to make
increases by a factor of 5, and the Cu-on-CoFe in- the CoFe and Cu layers miscible [56].
terface by a factor of 6.8. This is observed even though
the distribution of the oxygen surfactant does not ap- 3.5. Media materials
pear to change after annealing, as can be seen from a
comparison of the atom maps shown in Fig. 15 (as-de- New information storage systems require not only the
posited) and Fig. 17 (following annealing at 300 °C for development of new read/write heads but also of new
30 min). It is likely that in the layers that are grown with storage media. The media used currently in hard disk
oxygen, and thus are further from equilibrium, the re- drives consist of Co–Cr alloys (to which additional al-
duced conformal roughness provides a driving force for loying elements such as Ta are frequently added) in
which the information is stored with the magnetisation
vectors in the plane of the film (longitudinal media). The
high storage density is achieved in the media by having a
polycrystalline film in which the grains are small and are
ideally magnetically decoupled from each other. Mag-
netisation studies of the films suggested that this occurs
because of compositional inhomogeneities in the CoCr
alloy layer [72] and this was confirmed by TEM studies
[73]. However the exact way in which the inhomogenei-
ties were distributed in three-dimensions had not been
well understood. The grain size in this type of material is
typically of the order of a few nanometres and this is
therefore an ideal topic to be addressed by 3DAP.
A small number of atom probe field ion microscopy
studies had been made of Co–Cr alloy thin films, both by
deposition of the films on curved surfaces [22] and using
the Hasegawa method [32] and more recently studies
have been made using 3DAP. Hono et al. [74] used the
Hasegawa method to prepare thin films of a Co–
22at%Cr alloy that had been deposited on a heated
substrate, as would be the case for the thin film media
layer on a hard disk. Their results showed that the films
consisted of a ferromagnetic phase and a paramagnetic
Cr-rich phase, both with a lamellar-type structure, which
coexist within each grain of the film. The lamellar shape
of the Co-rich ferromagnetic phase results in the particles
having a high shape anisotropy which increases their
thermal stability, and the presence of the paramagnetic
phase acts to isolate the ferromagnetic lamellae mag-
netically from each other. Further work on a similar
system was carried out by Nishikima et al. [75] on a Co–
12Cr–2Ta alloy thin film deposited at elevated temper-
ature. The addition of the Ta to the alloy resulted in
segregation of the Cr to the grain boundaries, leading to
Co-rich ferromagnetic grains, as shown in the Co con-
Fig. 17. Atom map from 3DAP data for the CoFe/Cu MLF deposited
using Ar + oxygen, following annealing at 300 °C for 30 min. The centration map in Fig. 18(a), enveloped by a Cr-rich non-
oxygen atoms (large, pale spheres) and Cu atoms (small, dark spheres) magnetic phase, seen in Fig. 18(b), but still with some
are shown. non-uniformity in the Cr composition within the grains.
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