Owing
to the lack of large-diameter and affordable AlN bulk crystals,
high-quality AlN films grown on sapphire substrates have been intensively
analyzed for the potential applications in optoelectronic and electronic
devices. Herein, we successfully fabricated low-defect-density AlN
thin films on large-offcut-angle sapphire substrates combining magnetron
sputtering and metal–organic chemical vapor deposition. It
is found that the crystalline qualities of AlN films strongly depend
on the densities and geometric features of atomic steps. When high-density
zigzag macrosteps are formed on the surface, they can induce dislocation
inclination toward multiple directions rather than a single one. In
this situation, the inclined dislocations can interact with not only
vertical dislocations but also other inclined dislocations. Profiting
from the large inclination angles (30–78°), the lateral
interaction range of dislocations exhibits a 6-fold increase at most,
leading to more frequent dislocation interactions within a relatively
thin layer. As a result, the threading dislocation density value of
1 μm thick AlN is reduced down to 1.4 × 109 cm–2, demonstrating an 80% decrease in comparison with
its counterpart without the macrostep-induced dislocation redirection
effect. This approach is expected to boost the development of low-cost
and high-performance devices on AlN/sapphire templates.