We couple halide
vapor phase epitaxy (HVPE) growth of III–V
materials with liftoff from an ultrathin carbon release layer to address
two significant cost components in III–V device - epitaxial
growth and substrate reusability. We investigate nucleation and growth
of GaAs layers by HVPE on a thin amorphous carbon layer that can be
mechanically exfoliated, leaving the substrate available for reuse.
We study nucleation as a function of carbon layer thickness and growth
rate and find island-like nucleation. We then study various GaAs growth
conditions, including V/III ratio, growth temperature, and growth
rate in an effort to minimize film roughness. High growth rates and
thicker films lead to drastically smoother surfaces with reduced threading
dislocation density. Finally, we grow an initial photovoltaic device
on a carbon release layer that has an efficiency of 7.2%. The findings
of this work show that HVPE growth is compatible with a carbon release
layer and presents a path toward lowering the cost of photovoltaics
with high throughput growth and substrate reuse.