Diamond-Like Carbon: State of Art
Diamond-Like Carbon: State of Art
Abstract
   Diamond-like carbon films, amorphous hydrogenated or non-hydrogenated forms of carbon, are metastable amorphous
materials characterized by attractive mechanical, optical, electrical, chemical and tribological properties. The films can be prepared
at low temperatures by different techniques using a large variety of precursors and can be modified by incorporation of different
elements such as N, F, Si or metals. The diversity of methods used for the deposition of diamond-like carbon films provides the
flexibility to tailor their properties according to specific needs and potential applications. The hydrogenated form of DLC appears
to reach a maturity in understanding its properties and finding old and new practical applications for it. The non-hydrogenated
diamond-like carbon, or tetrahedral carbon, is at a much younger state of preparation and characterization and practical
applications have yet to be proven. The paper will review the state of the art of the preparation of the different types of diamond-
like carbon films, the characterization and understanding of their properties, and their practical applications. © 1999 Elsevier
Science S.A. All rights reserved.
0925-9635/99/$ – see front matter © 1999 Elsevier Science S.A. All rights reserved.
PII: S0 9 2 5- 9 6 3 5 ( 9 8 ) 0 0 26 2 - 3
                                     A. Grill / Diamond and Related Materials 8 (1999) 428–434                             429
techniques (sputtering or ion beams) using a variety of             films appears to reach a maximum at impinging particle
precursors, as described in detail elsewhere [3]. In the            energy of about 100 eV [9].
PECVD methods, the substrates have to be at a negative
bias relative to the plasma to achieve ion bombardment              2.2. Modified DLC and taC
of the growing film. The deposition is performed in
hydrogen-containing environments to obtain DLC films                   Various materials derived from the diamond-like
containing 10–50 at.% hydrogen. The hydrogen is                     carbon films have been developed to change and improve
required for obtaining ‘‘diamond-like’’ properties in               their properties. Such materials are similar in structure
these materials. It determines the film structure, passi-           to DLC or taC but, in addition to carbon and/or
vates the dangling bonds in the amorphous structures,               hydrogen, include nitrogen (NDLC or CN films), sili-
                                                                                                                  x
thus controlling the optical and electrical properties,             con (SiDLC ), silicon and oxygen, fluorine ( FDLC ),
and affects the internal stresses of the films. In most             and metal atoms (MeDLC ). Most modifications have
cases the deposition is a line-of-sight technique and the           been made to DLC to reduce its, typically high, internal
film is deposited on only one surface of the substrate.             compressive stresses (N, Si, metal incorporation), to
Industrial tools based on this technique have been                  reduce its surface energy [14] for further lowering, its
developed and are used in manufacturing. Deposition                 already low, friction coefficients (F, Si–O incorporation)
of DLC films by a high density plasma in a helical                  [3,4,15], or to modify its electrical properties [16,17].
resonator PECVD process has also been reported [5].                 Nitrogen incorporation has been used to improve field
The growth and properties of DLC films are controlled               emission properties of both DLC and taC [18,19]. Si
by the substrate temperature and bias, the latter having            incorporation in DLC has been found useful in reducing
the dominant control [3]. The hardness, density and                 the etching rate of DLC in oxygen plasma and makes
refractive index of the films increase with increasing              it useful as an etch stop for undoped DLC [16 ]. The
substrate bias. The deposition rates also usually increase          modified diamond-like carbon films are deposited by
with increasing bias. Even for films deposited in a helical         the same techniques as the regular films by adding
resonator, the substrates had to be biased negatively to            species containing the modifying elements to the depos-
obtain diamond-like properties. Films deposited in this             ition environment and details can be found in the
reactor on grounded substrates had polymeric character-             references cited above.
istics [5].
   A more recent technique for deposition of DLC films
is the plasma source ion implantation (PSII ) [6 ]. In this         3. Properties
technique, the substrates are placed directly in a plasma
source and then pulse-biased. This is a non-line-of-sight           3.1. Structure
technique and enables the coating of complex structures.
Another non-line-of-sight technique for deposition of                  Diamond-like carbon films are amorphous materials
DLC has been demonstrated in an ionitriding tool in                 with carbon atoms bonded in mainly sp3 and sp2 hybrid-
which DLC has been deposited by bipolar-pulsed DC                   izations. Diamond-like carbon is a low-mobility semi-
PECVD [7]. The films have been found to have proper-                conductor, with a bandgap of 1–4 eV, room temperature
ties similar to RF PECVD-deposited films, with the                  photoluminiscence and low electron affinity [20]. The
advantage of being deposited in an existing industrial              properties of the films are determined by the relative
reactor.                                                            ratio of the two hybridizations. DLC films can have
   The superhard properties of taC films are achieved               sp3 fractions up to about 40% [21], while taC can reach
by the high energies of the impinging particles that form           sp2 fractions of up to 87% when deposited at ion energies
the films. It is assumed that in this case the films grow           of about 100 eV [9,22]. Angus and Jahnsen [23] have
by subplantation, instead of by the conventional conden-            described the structure of hydrogenated DLC by a
sation, as in the case of DLC films [8]. The required               random covalent, fully constrained, network model.
high energies of the depositing species are achieved by             According to this model, the DLC structure can be
different variations of vacuum or cathodic arc dis-                 described as a three-dimensional array of mostly six-
charges, such as filtered arc [9], pulsed arc [10], laser           membered rings, which is able to contain 17–61 at.%
controlled arc [8,10], pulsed laser depositions [8,11] or           bound hydrogen. The role of hydrogen in controlling
mass selected ion beams [12]. Vacuum arc discharges                 the properties of DLC has been discussed in detail
can cause local overheating of the cathode and micro-               elsewhere [3,24].
spaling, resulting in deposition of rough films. Such                  Robertson [25] modeled the structure of diamond-
problems can be overcome by the mentioned modifica-                 like carbon in 1986 as a random network of covalently
tions of the techniques to deposit smooth and very hard             bonded carbon atoms in the different hybridizations,
taC films. The PSII technique can also be used for the              with a substantial degree of medium range order on the
deposition of taC films [13]. The sp3 fraction in the taC           1 nm scale. In a recent refinement of his model,
430                                  A. Grill / Diamond and Related Materials 8 (1999) 428–434
Roberston describes the structure of both DLC and taC               internal stresses. These properties are directly correlated
as being controlled by the energy of the p bonding of               to the fraction of sp3 C in the films. The hardness of
the sp2 sites [20]. According to Robertson, the p bonding           DLC films is in the range 10–30 GPa [28], with a
of the sp2 carbon favors clustering of sp2 sites to                 corresponding Young’s modulus 6–10 times larger. The
maximize the p-bonding energy. The sp2 sites can gain               films are characterized by internal compressive stresses
further energy by forming sixfold planar ‘‘aromatic’’               in the range 0.5–7 GPa. The stresses can be reduced by
rings and fusing the rings into larger graphitic clusters.          incorporating N, Si, O or metals in the films [13,24],
However, the energy gain resulting from increasing                  although the reduction in stresses is often associated
cluster size beyond pairing is small, therefore, the cluster        with a reduction in hardness and elastic modulus of
size remains small. For planar graphitic clusters of sp2            the films.
carbon, the band gap was found to be given by                          The hardness of taC films can reach higher values (in
E =6/M1/2 eV, where M is the number of sixfold rings                the range of 40–80 GPa) [8,22], and their Young’s
  g
in the cluster [25]. According to Robertson, the small              modulus can reach values up to 900 GPa [10], but the
sp2 clusters cannot explain the small bandgap of DLC                stress can also reach high values up to 13 GPa [22]. The
and the small bandgap is caused by the fact that the                high internal stresses limit the thickness of films that
distorted clusters have much smaller bandgaps [20]. The
                                                                    can be used for any application, often to less than 1 mm
bandgap is therefore controlled by the distortion of the
                                                                    thick. The stresses in taC have been reduced by incorpo-
clusters and not their size. Robertson also found that
                                                                    ration of metals [13] or by building multilayered struc-
the optical gap of all types of diamond-like carbon,
                                                                    tures comprising soft and hard films using a filtered
hydrogenated or non-hydrogenated, depends mainly on
the sp2 fraction in the films and decreases with increas-           vacuum arc and varying the ion energy during composi-
ing sp2 fraction. Non-hydrogenated taC, which has                   tion [29,30]. The bias of the substrate was changed
small sp2 fractions, has a very rigid network, while                between −100 eV (to obtain the hardest layers with an
hydrogenated DLC has a softer polymeric network, yet                sp3 fraction of 85% and hardness of 60 GPa) and −2 kV
both types of films have similar bandgaps.                          (to deposit soft films with an sp3 fraction of 39%) [30].
                                                                    The multilayered structures had hardness (40–23 GPa)
3.2. Characterization                                               and modulus (350–245 GPa), corresponding to the frac-
                                                                    tion of the hard and soft layers, and the stresses in the
   The structural characterization of diamond-like                  films were reduced in the multilayered films from
carbon films is complicated by their amorphous nature.              10.5 GPa, for the hard film, to 3.8 GPa, for the film
High resolution nuclear magnetic resolution (NMR)                   containing a 90% soft fraction.
spectroscopy with its recent refinements [21] appears to
be the best technique for characterization of the carbon            3.4. Material stability
hybridization of hydrogenated DLC. Fourier transform
infrared spectroscopy ( FTIR) is still being used by some              Both the hydrogenated and non-hydrogenated DLC
authors to quantify the carbon hybridization ratios and             are metastable materials and their structures will change
hydrogen content in DLC films, in spite of the fact that            towards graphite-like carbon by either thermal activa-
it has been shown that the technique can give erroneous             tion or irradiation with energetic photons or particles.
information [26 ]. Electron energy loss spectroscopy                Heating of hydrogenated DLC films results in the loss
( EELS ) has become the established method to measure               of hydrogen and CH species, starting at about 400 °C,
the sp2 bonding fraction in non-hydrogenated taC [20].                                    x
                                                                    or even lower, depending on the deposition conditions
The technique is, however, not suitable for DLC, which              and the dopant contained in the films [3,16,17]. This
is sensitive to irradiation with an electron beam [27].             causes changes in the dimensions and properties of the
   FTIR can be used for qualitative characterization of
                                                                    material and limits the use of DLC in applications
different bonds in hydrogenated diamond-like carbon
                                                                    involving temperatures above 400 °C. The temperature
films or their modifications. Film compositions can be
                                                                    at which changes take place in the DLC films appears
determined by Rutherford backscattering ( RBS) analy-
                                                                    to be correlated to the power used for the preparation
sis of C and heavier elements and forward recoil elastic
scattering ( FRES) for H concentrations. Mechanical                 of the films [16 ]. The thermal instability of DLC films
properties are usually determined by nanoindentation                is generally associated with the loss of hydrogen, result-
measurements for hardness and Young’s modulus deter-                ing in a collapse of the structure into a mostly
mination and measurements of radius of curvature of                 sp2-bonded network.
coated substrates for stress determination [3,22].                     It has been reported that thermal activation can also
                                                                    induce changes in taC films and cause the conversion of
3.3. Mechanical properties                                          some sp3 carbon bonds to sp2 bonds [31]. The onset of
                                                                    relaxation started at temperatures as low as 100 °C and
  Diamond-like carbon films are characterized by high               near full relaxation has been observed at 600 °C. An
hardness and a high elastic modulus, but also by high               activation energy in the range of 1–3 eV has been
                                    A. Grill / Diamond and Related Materials 8 (1999) 428–434                              431
reported for this thermal relaxation [31]. The thermal             DLC may have a lower stability then taC because of
relaxation reduced the internal stresses of the taC films          the hydrogen content [18].
and increased their electrical conductivity. However, it              DLC coatings have also been found to increase the
has been claimed at the present conference that taC                emission current from metallic FED tips [36 ]. Nitrogen
films can be stable at least up to temperatures of 600 °C.         incorporation in DLC coatings can enhance this effect.
   The diamond-like carbon films can also be changed               Thus, a 20 nm PECVD-deposited NDLC coating was
by UV [32] or ion beam irradiation [33]. Irradiation of            found to enhance the emission current from Spindt type
DLC in air with UV irradiation from a high pressure                Mo tips of a FED from 160 to 1520 mA [19]. The
mercury lamp was found to break C–C and C–H bonds                  surface roughness of the films can strongly affect the
and cause oxidation of the film with formation of C–O              field emission effects of DLC, as was observed for DLC
bonds [32]. CO , CH and H evolved from the film                    films deposited by laser ablation [11].
                 2       4        2
during the irradiation, resulting in a reduction of film              In spite of said above, it now appears that the field
thickness. UV irradiation of NDLC films containing                 emission from diamond-like carbon, or other forms of
about 11 at.% nitrogen resulted in a decrease in C–H               carbon films, is not related to electron affinity of the
bonding and an increase in C–C, CNN and CON                        materials, but is controlled instead by the nano-level
bonds. The sp2 cluster size in the films became smaller,           roughness of the films.
therefore, the optical gap increased. NDLC films with
high N content (~37 at.%) did not show any FTIR
changes after UV irradiation [32]. However, their optical          3.6. Tribology
gap increased, indicating a reduction of the cluster size
in the absence of material loss.                                      The widest use of diamond-like carbon films is mainly
   Room temperature irradiation of taC films with an               of the hydrogenated DLC in applications exploiting the
ion beam of 200 keV Xe+ transformed the material into              low friction coefficients and high wear-resistance of these
a conducting amorphous carbon with an sp2 fraction of              materials. It is therefore natural that a lot of efforts
0.6. At higher temperatures, the same irradiation                  have been invested in the characterization of the tribo-
increased the sp2 fraction to about 0.8 and increases the          logical properties of DLC. A recent review of the
degree of ordering towards a graphitic material [33].              tribological properties of DLC films and their modified
                                                                   forms [4] shows that, in all environments, the tribologi-
                                                                   cal behavior of DLC is controlled by an interfacial
3.5. Field emission                                                transfer layer formed during friction. The transfer layer
                                                                   is formed by a friction-induced transformation of the
   In the quest for finding new applications for diamond-          top layer of the DLC film into a material of low shear
like carbon, a significant effort has been directed in the         strength. This transformation may be caused by friction-
last few years to the investigation of the field emission          induced annealing, caused by thermal and strain effects
properties of DLC or taC. Flat panel field emission                generated during sliding [37]. The shear strength of the
displays (FED) use sharp Mo or Si tips for emission of             transfer layer and its adhesion to sliding surfaces can
electrons for the excitation of phosphor screen pixels.            be affected by the environment and by contact load and
The sharp tips are needed to obtain the high electric              sliding speed. The composition of the transfer layer can
field required to extract the electrons from these materi-         also be affected by the material of the sliding counter-
als which are characterized by a high work function of             part. The low friction and ultra low wear of DLC and
about 5 eV. The hydrogenated surface of diamond has                counterparts can be explained by the low shear strength
a negative electron affinity, therefore diamond or dia-            of the transfer layer [4], which can also be affected by
mond-like carbon films have the potential to serve as              the testing environment [38].
electron emitters for FEDs, without needing the 1 mm                  A compilation of friction coefficients of DLC films
lithography for the preparation of sharp tips [34]. It             [39] shows that the friction coefficients of DLC span a
was found that the threshold field for electron emission           range of m=0.007–0.4, in vacuum below 10−4 Pa, while
in the taC films reaches a minimum of about                        in ambient air at relative humidities of 20%<RH<60%,
10 V mm−1 when the films contain a high fraction of                they span a range of m=0.05–1.00. The large spread in
about 80% of sp3 bonds [18]. The addition of N to taC              the values of the friction coefficient are caused by
further reduced the threshold field, with the maximum              variations in the structure and composition of the films.
reduction of ~5 V mm−1 being obtained in taC contain-              The transfer layer described above has a lubricating
ing 1 at.% nitrogen. A further increase in the nitrogen            effect and its formation can be enhanced by hydrogen,
content reduced the sp3 fraction in the films, reduced             but may be restricted in the presence of water or oxygen.
the bandgap and increased the threshold voltage [18].              Water and oxygen were found to have different effects
Similar behavior has been observed in N-modified                   on the friction of DLC at low concentrations [40]. It
hydrogenated DLC [35], however, it is assumed that                 was also found that the hydrogen content of DLC has
432                                  A. Grill / Diamond and Related Materials 8 (1999) 428–434
to be above a threshold of about 40 at.% to obtain very             10−7 mm3 N−1 m−1, however the wear rate had a mini-
low friction coefficients in ultra high vacuums [41,42].            mum of about 3×10−8 mm3 N−1 m−1 for a multilayer
   Metal-containing DLC films have been found to                    modulated film containing 50% soft phase [29].
reduce friction and wear, not only in sliding, but also
in vibrating contacts for a broad range of testing condi-           3.7. DLC materials as low-k dielectrics
tions [43]. Fluorinated DLC with high F and low H
content having wear resistance similar to pure DLC has                 Special interest has recently been addressed to the
been demonstrated [15]. Because of the thermal instabil-            dielectric constant (k) of DLC and FDLC films
ity of DLC films, their wear behavior is temperature                [17,46,47]. Low-k materials are needed for the back
sensitive and that sensitivity will be affected by the              end of the line (BEOL) interconnect structures of ULSI
deposition conditions of the studied films. For some                ( Ultra Large Scale Integrated) circuits to improve their
films, the wear behavior in ambient air has been found              performance. It was found that, by adjusting the depos-
to change with temperature in the range 100–300 °C,                 ition conditions, it is possible to obtain DLC films with
with both the friction coefficient and wear resistance              the dielectric constant in the range 2.7–3.8 and FDLC
decreasing with increasing temperature [44].                        films with dielectric constants k<2.8 (as compared with
   Tribo-emission of electrons, negative and positive ions          k=4.0 for the presently used SiO dielectric). Integration
                                                                                                       2
and photons were observed during tribological tests in              of such films in the BEOL structures, however, imposes
ambient air, with diamond sliding over DLC, deposited               further requirements on the low-k material, such as low
by DC magnetron sputtering and containing 0–43 at.%                 stresses and thermal stability at 400 °C. It was found
hydrogen [45]. Photon emissions were observed only in               that, for the as-deposited DLC films, the intrinsic stresses
films containing >15% hydrogen, while particle emis-                decrease, but so also does the thermal stability, with
sions were detected also in films containing lower con-             decreasing k values [16 ].
centrations of hydrogen. The tribo-emission was                        FDLC films with dielectric constants k<2.8 have
explained by the formation of micro-plasma by dark                  been prepared having intrinsic stresses below 200 MPa.
discharge, at low hydrogen content, and spark dis-                  Both DLC and FDLC films could be stabilized by
charges, at higher hydrogen concentrations. Tribo-                  annealing in an inert ambiance [17,48] and a first
charging to local potentials up to several hundred volts            metallization level in a Cu-based damascene process
were observed. The friction coefficients of these films             with DLC as the dielectric has been demonstrated [48].
had very high values (0.6–0.8) in air [45].                         Such films become attractive candidates as low-k dielec-
   In contrast to DLC, very few results were published              trics for the BEOL interconnect structure, however
for the tribological properties of the non-hydrogenated             further integration issues have yet to be addressed
taC. Friction coefficients at RH=50% of taC films                   and solved.
deposited by a filtered cathodic vacuum arc have been
reported to correlate to the sp3 fraction in the films,
reaching values down to 0.08 [22]. The wear rates of
multilayered taC films described earlier were measured
at RH=30% [29]. The authors found that both soft
and hard monolithic films had wear rates of about
Fig. 1. Phase diagram of diamond-like carbon materials (from        Fig. 2. Delimitation of properties of diamond-like carbon (after
Ref. [20]).                                                         Ref. [60]).
                                           A. Grill / Diamond and Related Materials 8 (1999) 428–434                                         433
Table 1
Summary of properties and applications of diamond-like carbon films. Text in parentheses indicates potential applications
Transparency in Vis and IR;                  Optical coatings                            Antireflective and wear-resistant coatings for IR optics
  optical bandgap=1.0–4.0 eV
Chemical inertness to acids,                 Chemically passivating coatings             Corrosion protection of magnetic media, biomedical
  alkalis and organic solvents
High hardness; H=5–80 Gpa:                   Tribological, wear-resistant coatings       Magnetic hard drives, magnetic tapes,
  low friction coefficient=<0.01–0.7                                                     razor blades (bearings, gears)
Nanosmooth                                   Very thin coatings <5 nm                    Magnetic media
Wide range of electrical resistivities       Insulating coatings                         Insulating films
  =102−1016 V cm−1
Low dielectric constants <4                  Low-k dielectrics                           (Interconnect dielectrics)
                                             Field emission                              (Field emission flat panel displays)
  Another variation of the diagram of Fig. 1 is presented                    [29] J.W. Ager, III, S. Anders, I.G. Brown, M. Nastasi, K.C. Walter,
                                                                                   Surf. Coat. Technol. 91 (1997) 91.
in Fig. 2 (after Ref. [60]), which shows that the dia-
                                                                             [30] S. Anders, D.L. Callahan, G.M. Pharr, T.Y. Tsui, C.S. Bhatia,
mond-like carbon films, comprising sp3, sp2 and even                               Surf. Coat. Technol. 9495 (1997) 189.
sp1 carbon bonds, have ranges of properties delimited                        [31] S. Reinke, W. Kulisch, Surf. Coat. Technol. 97 (1997) 23.
by the properties of diamond, graphite and polymers.                         [32] M. Zhang, Y. Nakayama, J. Appl. Phys. 82 (1997) 4912.
These ranges of properties of hydrogenated and non-                          [33] D.G. McCulloch, D.R. McKenzie, S. Prawer, A.R. Merchant,
                                                                                   E.G. Gerstner, R. Kalish, Diam. Relat. Mater. 6 (1997) 1622.
hydrogenated diamond-like carbon are summarized in                           [34] J. Robertson, Mater. Res. Soc. Symp. Proc. 471 (1997) 217.
Table 1, together with existing and potential applications                   [35] G.A.J. Amaratunga, S.R.P. Silva, Appl. Phys. Lett. 68 (1996) 2529.
based on the specific properties of the material.                            [36 ] J.H. Jung, B.K. Ju, Y.H. Lee, M.H. Oh, J. Jang, in: Proceedings
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