In a chemical vapor deposition (CVD) process, a thin film of some material is deposited onto a surface via the chemical reactions of gaseous molecules that contain the atoms needed for the film material.These chemical reactions take place on the surface and in many cases also in the gas phase. To fully understand the chemistry in the process and thereby also have the best starting point for optimizing the process, theoretical chemical modeling is an invaluable tool for providing atomic-scale detail on surface and gas phase chemistry. This overview briefly introduces to the non-expert the main concepts, history and application of CVD, including the pulsed CVD variant known as atomic layer deposition (ALD), and put into perspective the use of theoretical chemistry in modeling these processes.
KeywordsChemical Vapor Deposition, Atomic Layer Deposition, Thin Films, Surface Chemistry, Gas Phase Chemistry, Theoretical Chemistry 3
An introduction to vapor-phase deposition techniquesThin films are layers of materials with thicknesses ranging from less than one nanometer (a few atomic layers) to hundreds of micrometers (for reference, a human hair is about 75 µm thick) [1]. The importance of thin films in today's society is enormous and thin films can be found everywhere; from low friction coatings in a car engine to the anti-reflecting coating on the lenses of spectacles, as well as the decorative coating on their frames. Most metal objects around us have been machined by cutting tools that are coated with a hard, wear-resistant thin film. Replacement parts for the human body, such as hip-joints, are often coated with a thin film to make them more bio-compatible.Furthermore, today's nanoelectronic devices are built up very precisely from stacks of thin films of various materials with different electrical properties, with some of the films as thin as one atomic layer. Technologically important thin films can be amorphous, polycrystalline or epitaxially-grown single crystals and the properties of the materials can often be tuned with great precision to suit various applications.To coat an object (the "substrate") with a thin film, it is often preferred to start from atoms or molecules in a vapor phase and place the object(s) to be coated in that vapor, letting atoms and/or molecules from the vapor build up a thin film on the surface of the object. These vapor-based thin film synthesis methods are classified as either physical vapor deposition (PVD) or chemical vapor deposition (CVD), depending on whether the film deposition process is driven by physical impacts or by chemical reactions, respectively. Generating the vapor in the reactor is of course straightforward when the desired element is available in gaseous form, e.g. O 2 , but this is not the case for most elements. Therefore, in PVD, a solid sample containing the target elements is subjected to substantial energy, often in the form of a plasma or an electric discharge, thereby ejecting atoms and producing a vapor, which can then condense onto the substrate ...