Smoothing surface roughness using Al2O3 atomic layer deposition

[Display omitted] •Atomic layer deposition can smooth surface roughness.•Root-mean-square roughness reduced versus atomic layer deposition.•Lateral spacing between surface asperities increased versus atomic layer deposition.•Smoothing surface roughness improved reflectivity of silver mirrors. Al2O3 atomic layer deposition (ALD) was used to smooth the roughness on silicon wafers obtained prior to chemical mechanical polishing (CMP). The initial silicon wafers had an average RMS surface roughness of 3.3 nm as determined by atomic force microscopy (AFM) measurements. AFM line scans also measured an average lateral spacing of ≈490 nm between the surface asperities. The RMS roughness decreased and the average lateral spacing increased progressively with number of Al2O3 ALD cycles. After 3000 Al2O3 ALD cycles that deposit an Al2O3 film thickness of 370 nm, the RMS roughness reduced to 1.5 nm and the average lateral spacing between the surface asperities increased to ≈890 nm. Additional Al2O3 ALD cycles produced little change in the RMS roughness or average lateral spacing. The efficiency of the smoothing decreased when the lateral distance between the surface asperities was much larger than the Al2O3 ALD film thickness. Power spectral density (PSD) analysis revealed that the ALD smoothing was most effective for surface topographical features with lateral spacings in the range of 10s to 100s of nanometers. Reflectivity studies of silver films deposited on the silicon wafers also demonstrated that Al2O3 ALD smoothing improved the optical performance of reflective mirrors.