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We are investigating solid-state dewetting of thin films as a technique for producing ordered arrays of metal nanoparticles over large areas. Such arrays are used as catalysts for nanowire and nanotube growth and may also be of interest in memory or plasmon device applications. When we begin with a single crystalline film, the dewetted nanoislands align along specific crystallographic orientations and show regular patterns. We observe a strong dependence of the morphological evolution of single crystalline nickel thin films on the thickness of the film and on the crystallographic orientation of the film, which is determined by an epitaxial relationship with a magnesium oxide substrate. The resulting nanoparticles remain epitaxial and thus share both in- and out-of -plane crystallographic alignment. In order to obtain similarly ordered dewetting with polycrystalline films, we employ physical templates. One technique is to physically constrain the area of film that dewets by pre-patterning a polycrystalline gold film on silicon dioxide. We observe that certain geometries lead to self-alignment of the dewetted nanoparticles (see Figure 1). Ongoing investigations will further characterize how film thickness and pattern dimensions affect the self-alignment. | Another technique for ordered dewetting of polycrystalline films is the use of topographic templates to modulate the curvature of as-deposited films. Gold films dewetted on di-periodic arrays of oxidized pyramidal pits in silicon result in one-to-one self-assembly of ordered arrays of gold particles over large areas. Compared to dewetting on flat substrates, the templates impose a significant decrease in average particle size and ensure a narrow size and spatial distribution. In this case, this technique results in crystallographic ordering of the particles, imposing an in-plane texture and changing the out-of-plane texture [1]. We observe similar spatial ordering behavior with other materials, including nickel (see Figures 2a and 2b) and cobalt; however, these materials have not demonstrated the crystallographic ordering effect. We have also combined pre-patterning with dewetting on topography to produce monodisperse Au particles. Heating allows controlled evaporation to produce populations of particles with smaller average size and a narrowed distribution of sizes (see Figures 2c and 2d) [2]. | |
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| Figure 1: Rows of Au particles formed by dewetting of 30-nm thick films as a) 1.3 μm x14.5 μm and b) 1.3 μm x18 μm.
| Figure 2: Solid-state dewetting on substrates with inverted pyramid array topographies. (a and b) Transmission electron micrographs of ordered Ni nanoparticles. (c) Scanning electron micrograph of Au nanoparticles. (d) Distribution of nanoparticle diameters obtained by annealing Au layers with thicknesses of 5 nm, 10 nm and 20 nm at 1000 °C for 60 min. |
References
[1] A.L. Giermann and C.V. Thompson, “Solid-state dewetting for ordered arrays of crystallographically oriented metal particles,” Applied Physics Letters, vol. 86, p. 121903, Mar. 2005.
[2] W.K. Choi, T.H. Liew, H.G. Chew, F. Zheng, C.V. Thompson. Y. Wang, M.H. Hong, X.D. Wang , L. Li, and J. Yun, “A combined top-down and bottom-up approach for precision placement of metal nanoparticles on silicon,” Small, vol. 4, no. 3, p. 330, 2008.

