In this study, the process of surface morphology control
was researched
by combining the computation fluid dynamics (CFD) simulations and
physical vapor transport (PVT) growth experiments. The results indicate
the essentiality of preserving the surface structure of SiC substrate
with macroscopic steps at the initial stage of the heterogeneous PVT
growth. We identified an optimal range of growth temperature (T
g) and pressure to maintain the active Al vapor
below a critical threshold. In the subsequent process, the pivotal
factor for controlling the surface morphology of the AlN layer is
identified as the supersaturation near the growing surface. Excessive
supersaturation leads to a transition from a 2D to a 3D growth mode,
resulting in a shift from a smooth to a rough surface morphology.
An appropriate level of supersaturation can be achieved by carefully
controlling the T
g, striking a balance
between high surface quality and growth rate. Herein, we proposed
a two-step PVT method for cultivating high-surface-quality AlN crystals
on SiC substrates. At the first stage, the T
g is maintained below a threshold corresponding to the critical
Al vapor pressure to preserve the surface structure until the SiC
surface is completely covered by AlN. Then, T
g is elevated to near transition temperature (T
tran) to continue AlN single crystal growth at a proper
rate for a long time, where T
tran is defined
as the growth temperature at which the transition of the dominant
mode from step growth to 3D growth happens. Two-inch-diameter AlN
single crystals of thicknesses of nearly 1 mm with a smooth and lustrous
surface have been obtained on SiC substrate by the two-step method.