Materials Science and Engineering R 43 (2004) 103–138 Nanometric superlattices: non-lithographic fabrication, materials, and prospects H. Chik, J.M. Xu* Division of Engineering, Brown University, Box D, Providence, RI 02912, USA Abstract A non-lithographic technique that utilizes the self-organized, highly ordered anodized aluminum oxide (AAO) porous membrane as a template is employed as a general fabrication means for the formation of vastly different twodimensional lateral nanometric superlattices. The fact that material systems as different as metals, semiconductors, and carbon nanotubes (CNT) can be treated with the same ease attests to the generality of this nano-fabrication approach. The original alumina nanopore membranes determine the uniformity, packing density, and size of the nanostructures. The flexibility of using a variety of materials, the accurate control over fabrication process, and the command over the alumina template attributes give us the freedom of engineering various physical properties determined by the shape, size, composition, and doping of the nanostructures. The novel nanomaterial platform realized by this unique technique is powerfully enabling for a broad range of applications as well as for uncovering new physical phenomena such as the collective behavior of arrays of nano-elements that may not be intrinsic to individual nano-elements. # 2003 Elsevier B.V. All rights reserved. Keywords: Superlattices; Non-lithographic; Collective behavior; Nanotechnology; Quantum dot; Semiconductor devices 1. Introduction 1.1. Motivation: a single’s nano world thus far Nanotechnology has become the subjects of much interest, intensive research, and in some instances, a profitable enterprise. However, the march towards nanotechnology has been underway long before it became fashionable, and in this regard, it is merely a natural step along the onedimensional path of miniaturization in the microelectronics evolution. Nevertheless, the ability to engineer at the nano-scale does offer us something new and broadly important. It offers us access to a qualitatively new paradigm in science and engineering, largely because the nano-scale is comparable to the ‘‘electron wavelength’’ in electronic materials and to the sizes of most biological molecules. From this perspective, engineering materials on the nano-scale is more than a fashion and worth of investing in, for it can and will enable controlled alteration, dynamical manipulation, and molecular functionalization of material properties, and potentially create entirely new properties that are not intrinsic to the material in the bulk and in individual nano-element forms and open access to regimes of material functions previously inaccessible. * Corresponding author. E-mail address: [email protected] (J.M. Xu). 0927-796X/$ – see front matter # 2003 Elsevier B.V. All rights reserved. doi:10.1016/j.mser.2003.12.001 104 H. Chik, J.M. Xu / Materials Science and Engineering R 43 (2004) 103–138 Technologically, the pursuit for nano-scale engineering has been powered by modern lithographic and contact printing techniques, and has been mostly focused on explorations of individually crafted nanostructures. Many of these achievements are astonishing including: single nanotube field-effect transistor [1]; single electron transistor [2]; logic functionality from nano-networks [3,4]; single nanowire electrically pumped laser [5], etc. As a first step into the nano-realm, investigation of isolated nanostructures and characterization of single nanodevices are of great importance and naturally of strong appeal to researchers. However, a more challenging and perhaps of great potential for novel applications is the collective behavior of nanostructures in a large ensemble and the manipulation of multiple nanostructures into integrable functional units during which the properties of the system as a whole may be fundamentally altered and have no classical or individual-based characteristics. Thus, it is both desirable and natural to take the next step and seek for ways to advance both the fabrication capabilities and the science explorations beyond the realm of individual nanostructures. 1.2. Collective behavior A not yet heated but no less interesting space of nanostructured materials is that of the collective properties (behaviors) of large assembles of coupled nano-elements giving rise to emergent responses of a system as a whole that are not intrinsic to individual nano-elements. Collective behavior is more complex than examining the properties of the elements in isolation as it involves unique interactions of a group of nano-elements acting together, however, a better understanding of the intricacies can be highly rewarding in the design principles of robust, flexible, and decentralized physical systems that are resistant to errors, adaptive, self-organize, and capable of acquiring information and executing on the information. One example of such a system is the ant colonies as the communication and interaction between relatively simple individual organisms give rise to an effective survival strategy for the colony as a whole. Borrowing from biology, a more complex example would be the behavior of individual neurons and how they act together in the human brain to perform bodily functions. In photonics, one extraordinarily well popularized example of interesting behaviors arising from couplings is the so-called photonic band gap crystals, which is essentially an extension of the Bragg gratings from one dimension to three dimensions in real space, that rely on couplings on the length scale of half or quarter optical wavelengths. In the near-field coupling regime, the spacing between adjacent nano-elements is on the nano-scale, much smaller than the optical wavelengths. As such, it enables drastically different coupling mechanisms, both the short-range couplings via electronic tunneling and the short-range photonic tunneling (that is, coupling via an optical field not yet emitted), as well as the long-range EM field couplings. In this regime, synchronized (coherent) resonant excitations and responses of the nano-elements can be extraordinary and give rise to unexpected or entirely new properties or behaviors in otherwise familiar and ordinary materials. Understanding of the unique properties arising from the collective behaviors of such lateral superlattices in the presence of near-field couplings due to the sub-wavelength and periodic spacing, and coherent interactions with an incident or emitted radiation field will enable us to explore, design, and demonstrate novel nano-electronic, nano-photonic, and nano-magnetic devices, and functional subsystems based on this new class of nanostructured materials. H. Chik, J.M. Xu / Materials Science and Engineering R 43 (2004) 103–138 To begin to investigate the interesting regime of strong collective electronic and photonic couplings, structures and systems with critical feature sizes much smaller than the wavelength of interest need to be fabricated. However, the features of the desired nanometric structures (2D or 3D superlattices) including good nano-element uniformity over a large scale area are often beyond the reach of conventional fabrication techniques. 1.3. Scope and aim of the paper It is intuitively clear that maximum collective resonance effects in this regime would require large arrays of highly ordered and highly uniform nano-elements. Fabricating such large arrays of nanostructures poses a challenge to even the best developed nano-fabrication technique—the electron beam lithography, because of its low throughput due to its long exposure time, small field size, and high cost of equipment. On the other hand, a few new nano-fabrication approaches appear to be well poised to meet this challenge. A non-lithographic nanopore template based approach is particularly encouraging and is the chosen focus for this review. The non-lithographic nano-fabrication approach of interest to us in this article utilizes highly ordered hexagonally packed straight nanopore arrays formed via self-organization in a carefully controlled process of anodizing high-purity aluminum. Using the anodized aluminum oxide (AAO) membrane as a template, a set of non-lithographic methods for nano-fabrication have been developed and applied to the formation of a wide variety of nanometric superlattices including nanodots, nanowires, nanopillars, and nanopores. The fabrication of these nanostructures have been demonstrated in metals, semiconductors, and polymers, and will be described in this article. Taking advantage of its hexagonal symmetry, the highest packing form for a given diameter and spacing, applications utilizing the periodic nanometric superlattices will also be described. 2. AAO membrane: a highly ordered template 2.1. Properties Fabricating nanostructures and tailoring their properties on the length scales less than 50 nm by conventional lithographic approaches is quite challenging. And, making them into large highly ordered and uniform arrays, to enable and enhance desirable collective behaviors, is even more difficult. Such difficulties have compelled many including us to seek alternative approaches such as utilization of recent developments in chemical synthetic methods to produce uniform nanostructures on these length scales, and to form self-organized highly ordered superstructures (i.e. multidimensional superlattices). Central to the non-lithographic, nano-fabrication method favored here is the utilization of an alumina nanopore membrane as either the growth template, or the etch or evaporation mask for the formation of the proposed nanostructures. The alumina nanopore array is formed by anodization of high-purity aluminum under certain carefully controlled anodization conditions. The nanopores can self-organize into a highly ordered array of uniform pores with the pore diameter, the period, and the array size being variable over ranges that are beyond the reach of standard e-beam lithography. As an example, Fig. 1 is a hexagonally packed template with 55 nm diameter pore sizes spaced 110 nm apart. Anodic porous alumina has been studied in detail over the last five decades [6–9]. In the anodization process, an electrical circuit is established between a cathode and a thin film of 105 106 H. Chik, J.M. Xu / Materials Science and Engineering R 43 (2004) 103–138 Fig. 1. Anodized aluminum oxide (AAO) membrane with pore diameter of 55 nm and pore spacing of 110 nm: (a) top view and (b) cross-sectional view. aluminum which serves as the anode, according to following reaction: 2Al þ 3H2 O ¼ Al2 O3 þ 3H2 ; DG ¼ 864:6 kJ where DG is the standard Gibbs free energy change. During the anodization, initially a planar barrier film forms followed by pore development leading to the formation of the relatively regular porous anodic film, which thickens in time [10]. This barrier film is maintained during further oxide growth as a semi-spherical oxide layer at pore bottoms as shown in the schematic in Fig. 2. The formation of regular nanopore structures actually means that, for some reason, micro-heterogeneity of the oxide comes into play resulting in easier dissolution of the oxide at some points than at others, thus implying a varying dissolution rate constant over the surface. A steady-state pore growth regime is reached characterized by the balance between the field-enhanced oxide dissolution at the oxide/ electrolyte interface at the pore bottoms and the formation of oxide at the metal/oxide interface due to migration of O2/OH ions through the bottom oxide layer. The cell and pore diameters, and the barrier layer thickness are directly proportional to the formation voltage [11]. In 1988, Konno et al. [12] observed pore regularity in anodized aluminum oxide membranes. By 1995, Masuda and Fukuda [13] reported large defect-free regions appearing in large domains, while defects were found at the boundaries of these domains after a long anodization period under an H. Chik, J.M. Xu / Materials Science and Engineering R 43 (2004) 103–138 Fig. 2. Schematic of the semi-spherical oxide layer at the bottom of the AAO nanopore membrane. appropriate constant anodizing voltage. The long anodization time rearranges the cells and reduces the number of defects and dislocations. Bandyopadhyay et al. [14] showed that pores tend to nucleate in regions of increased surface elastic energy and grain boundaries are typically preferred sites. Although there is no direct evidence up to now that defects in the pore lattice can originate from dislocations or other defects in the aluminum, it is clear that the correlation of self-organization is at least disturbed by a large number of grain boundaries in the non-annealed aluminum foils. The high surface roughness leads to a faster formation of barrier oxide and pores at depressions in the surface compared to other smoother locations. The pores that nucleated at such depressions in an early stage will grow sooner than at other sites. The surface roughness is thus transferred to the anodization front, at the interface between the aluminum and oxide layer, and prevent selforganization. However, the stirring of the electrolyte may contribute to spatially homogenous etching conditions. Pre-annealing of the aluminum substrate can increase the grain size, while stirring of the electrolyte during oxidation, and using smooth electropolished aluminum surfaces are all necessary for obtaining ordered hexagonal structures with typical long-range ordering of 100 mm2. A two-step anodization process, illustrated in Fig. 3, can improve the pore regularity under particular conditions. In this process, after stripping away the thick aluminum oxide film obtained from the first long anodization, a porous thin alumina film with highly ordered pores can be obtained by a subsequent re-anodization under the appropriate conditions. While the physical mechanisms underlying this remarkable self-organization process are not yet understood, some compelling but incomplete hypothesis and models have been advanced in the literature. For example, a mechanical stress mechanism has been proposed to explain the selfordering of anodic alumina [15]. It was suggested that the repulsive forces between neighboring pores caused by mechanical stress at the metal/oxide interface promote the formation of hexagonally ordered pore arrangements. According to this hypothesis, under the usual experimental conditions, the volume expansion accompanying the aluminum oxidation gives rise to the mechanical stress at Fig. 3. Schematic of the two-step anodization process. The first anodization step pretextures the Al surface in a highly ordered manner which is retained during the second anodization. 107 108 H. Chik, J.M. Xu / Materials Science and Engineering R 43 (2004) 103–138 the interface between alumina and Al. The expansion strongly depends on experimental conditions such as the electrolyte concentration and anodizing voltage. The optimal conditions for the growth of ordered arrangements are accomplished by moderate expansion of the aluminum, whereas no ordered domains can be observed in the cases of contraction or very strong volume expansion. These observations suggest that the system could be modeled by a Gibbs energy function consisting of an elastic energy term, a volume energy term, and a surface energy term. The complication comes from the role of the chemical energy which has remained elusive from definitive experimental characterization, or explicit functional expression of key parameters. After the second-step anodization, the nanopore alumina can be separated from the Al base and further processed into a freestanding membrane of nanopores that is open on the top and bottom and be used as a base template stencil or mask for fabricating a variety of highly ordered nanostructures. The advantages of the non-lithographic fabrication using self-organized, highly ordered anodized aluminum oxide nanopore template include: uniform pore diameter adjustable from 20 to 200 nm; uniform pore periodicity from 50 to 400 nm; highest packing density 109–1011 cm2 due to its hexagonal symmetry; the pore diameter, the period, and the array size variable over ranges that are beyond the reach of standard e-beam lithography with the AAO template pattern completely replicated in dimensionality onto the receiving substrate; large area and low cost; process is not material specific ranging from oxides to semiconductors to metals to polymers; readily scalable and compatible with existing IC processing yet inherently not limited to existing wafer sizes; process conformal to arbitrary surfaces either flat or curved surfaces, both locally or globally; does not need a cleanroom process. 2.2. Pattern transfer Periodic porous oxide with remarkably ordered arrangement of cylindrical pores whose diameter variable in the range of 25–200 nm with pore spacings from 50 to 400 nm can now be realized routinely. The process typical begins with a high-purity aluminum film (99.98%), followed by electropolishing in mixed solution of HClO4 and C2H5OH for 3 min, and completed by a two-step anodization, in either oxalic acid, sulphuric acid, or phosphoric acid solution over several hours. Li et al. established that by varying the anodization conditions, hexagonal close-packed arrays with controllable variation of diameters, densities, and lengths can be formed defect-free over large areas [16]. A set of optimized anodization parameters in different electrolytes are shown in Table 1. The resultant nano-scale pores are parallel, straight, and oriented vertical to the surface. In addition, the nanopores are uniform in diameter and in spacing. Table 1 Typical anodization conditions for various electrolytes Electrolyte Concentration (M) Temperature (8C) Voltage (V) Typical pore diameter (nm) Sulphuric acid Oxalic acid Phosphoric acid 0.5 0.3 1.0 0 10 0 25 40 160 30 45 400 H. Chik, J.M. Xu / Materials Science and Engineering R 43 (2004) 103–138 Fig. 4. Generalized schematic illustrating the process flow for various nanostructures. After reaching the desired template thickness during the second anodization, the AAO membrane can be separated from the remaining aluminum foil using a 2% HgCl2 solution or by reversing the applied voltage of anodization to a negative bias. The resultant nanopores are open on one side of the membrane, while a thin Al2O3 barrier layer exists on the opposite side. Both wet etching in a 0.1 M phosphoric acid solution and plasma etching with CF4 þ O2 gas system are effective for removing the barrier layer and forming a through-pore membrane [19]. By using the AAO membrane as templates, stencils, or masks, a number of approaches for fabricating a variety of nano-superstructures have been developed. These approaches are not material specific. They are also scalable in principle, however, in practice the sizes of the arrayed nanopore membranes have been limited to the size on the order of a couple of centimeters due to the fact that they are sufficient for most research and development purposes and that large membranes are brittle to handle manually in the lab. The process flow diagram in Fig. 4 illustrates some of the possible ways of creating nanostructured arrays. In the sections to follow, we will describe the details of the fabrication processes for each of these primary classes of nanometric superlattices, namely: 1. 2. 3. 4. nanodot; nanowire and nanopillar; nanotubes; nanopores or nano anti-dots. It is already clear from the different pathways outlined in the schematic that the AAO templating method is extremely versatile and can be applied to a broad range of purposes and devices. 3. Nanodots 3.1. Fabrication The placement of metal nanodots on a substrate in a controlled manner has been achievable with the advent of e-beam lithography. Current e-beam writing machines can readily write one or a hundred or even thousands of nanodot patterns in e-beam photoresist with great accuracy and 109 110 H. Chik, J.M. Xu / Materials Science and Engineering R 43 (2004) 103–138 without extraneous efforts. However, when asked to write hundreds of millions of nanodots, the process would take extraordinary amount of time and also be limited by the microscopes field of view if stitching errors are to be avoided. Also, this does not account for complex proximity effect issues when deciding on exposure times which can dramatically alter the dimensions of the desired patterns especially with nanodots spaced about 100 nm or less. With the AAO templating method, billions of nanodots of uniform size and spacing can be formed in parallel often in one or a few steps. The fabrication of metal nanodots starts with the nanopore AAO membrane with the barrier layer removed leaving a through-pore template. The template is then placed onto the substrate done usually in solution as the membrane, being as thin and as large as possible, can be easily fractured in manual handling. The template adheres well and strongly to a flat substrate because of the Van der Waals force. Afterwards, a thin metal layer can be evaporated through the pores onto the substrate surface. Evaporation is typically performed in an e-beam evaporator at a relatively slow deposition rate as faster rates tend to clog the nanopores more easily. After peeling off or etching away the AAO template, undesired metal is also lifted off, much like a conventional lift-off process in semiconductor processing, and a perfect hexagonal array of metal nanodots is formed naturally on the hosting (e.g. semiconductor) substrate. The mean diameter and spacing of the nanodots are limited by, and thus can be varied with, the pore diameter and spacing of the AAO membrane. The dot diameter can be reduced further post lift-off by wet chemical etching. A typical nanodot array is shown in Fig. 5. Here, a Ni nanodot array on a Si substrate with 55 nm diameter nanodots and a periodicity measuring the center-to-center spacing between two neighboring dots 110 nm is shown in the SEM image. The height of the metal nanodots, determined to be 30 nm by AFM, can be adjusted by controlling the evaporation thickness or by post-evaporation etching. To reach a metal nanodot height of 30 nm, 100 nm thick Ni was evaporated as indicated by the thickness monitor. The nanodots are in the shape of a cone likely due to the finite solid angle of the impinging beam and due to the relatively large aspect ratio of the pore (50:500 nm). It is also possible that as evaporation continues, metal accumulates at the bottom of the nanochannel (surface of substrate), but also on the sidewalls reducing the diameter of the nanochannel resulting in a conical shaped nanodot. The highly ordered magnetic (Ni) nanodot arrays provide us an enabling platform for exploiting the collective Fig. 5. Ni nanodot array with 55 nm diameter and 110 nm spacing mimicking the AAO template dimensions. The scale bar is 100 nm. H. Chik, J.M. Xu / Materials Science and Engineering R 43 (2004) 103–138 Fig. 6. MBE grown GaAs nanodot array on GaAs substrate with (a) top view and (b) oblique angle view from [20]. behaviors of such arrays for low-power, room temperature, high-density information storage, as well as information processing. The process is non-selective to either target metal materials or substrate materials. Different metal nanodot arrays, such as Au [17], Ni [18,19], Co, and Fe, have been deposited in a similar fashion on various substrates such as Si, GaAs, and GaN. The ability to form metallic nanodots on a substrate provides the platform for etching nanopillars and growing nanowires, as will be described in proceeding sections. However, nanodots need not to be confined to just the metallic variety although evaporating metal through the nanopore template is a simple process, GaAs nanodot arrays have been grown on GaAs (0 0 1) substrates through the nanopore template by molecular beam epitaxy (MBE) [20]. Mei et al. observed disk-like shaped with a slightly convex surface as shown in Fig. 6, but also pyramidal-like GaAs nanodots depending on the growth rate used. Higher growth rates produced disk-like nanodot shapes indicating layer-by-layer growth mode, however, greater portions of the GaAs material deposited on the AAO template surface and not within the nanochannels on the surface of the substrate. The ratio of material depositing inside the nanochannel or on top of the nanopore membrane was improved with lower growth rates, however, this resulted in the pyramid-like shaped nanodots indicating the growth mode was not layer-by-layer. The thickness of the AAO template was from 120 to 150 nm allowing the Ga beam to penetrate through the nanochannels as the growth mechanism is migration dominated with no nanodot growth when templates are greater than 300 nm thick. From these demonstrations, we observe that a third 111 112 H. Chik, J.M. Xu / Materials Science and Engineering R 43 (2004) 103–138 Fig. 7. Two spatially resolved Au nanodots evaporated through each nanopore on Si from [21]. deposition route seems to be feasible as well in which a metallic nanodot array, such as Cd, is formed by evaporation then converted into compound semiconductor nanodots such as CdS. Beyond the capabilities of e-beam lithography is the formation of nanodot arrays whereby each nanodot comprises of multiple metals in a 3D structure. Fabrication of ordered arrays of multimaterial composite nanodots maybe desirable to enable new optical or catalytic properties of nanoparticles. Using the AAO template as an evaporation mask, identical to the single metal nanodot formation as described previously, and by tilting the sample (AAO template attached onto the substrate) to an appropriate angle, shadowed evaporation can occur. Shadowed evaporation creates spatially resolved deposition as the effective aperture, i.e. metal with a straight line path from the template opening to the bottom of the nanochannel, diminishes to only one section of the nanopore at the surface of the substrate. Masuda et al. deposited two and three nanodots with the same or differing composition in each nanopore as reported in Fig. 7 [21]. In the SEM image shown, two Au nanodots sit on a Si substrate produced by a single nanochannel. A bimetallic nanodot array can be created simply by switching the metals being evaporated. The authors demonstrated Au and Ag nanodots as well as three (Au, Ag, and Si) nanodots created by a single nanochannel. 3.2. Examples of applications Circular nano-magnet arrays are being developed for use in random access memory (RAM) devices. Magnetic nanodot arrays also can be deployed to affect Faraday rotation in waveguides or vertical cavity surface emitting lasers (VCSELs). The template method allows large-scale fabrication of uniformly sized and site controlled magnetic nanodot arrays, and offers a number of advantages, such as smaller minimum sizes over conventional photolithography, and larger array size and lower costs over e-beam lithography. Two of the biggest problems today’s microelectronics face are power dissipation and interconnection. When compared to the also significant challenges of device miniaturization and the major costs associated with building next generation fabrication lines, these two problems are more fundamental and rooted in the binary serial architecture. While nano-scale devices based on molecular-scale elements have been demonstrated, such devices still face the difficult interconnection problems if large-scale integration is to be attempted. Furthermore, since power dissipation from H. Chik, J.M. Xu / Materials Science and Engineering R 43 (2004) 103–138 prototype molecular devices is on the order of microwatts, thermal management will continue to be a major design challenge even if devices are greatly reduced in size [22,23]. The study of magnetic nanostructures could enable us to move beyond the realm of information storages into information processing. Nanocomposite materials and engineered nano-magnetic arrays appear to be promising systems for exploring magnetic interaction modes which are not possible in naturally occurring or bulk materials. Additionally, nano-magnetic dots not only have the potential to each represent 1 bit of information, which can be highly stable, but also could act collectively to process and transmit information in a cellular automata or a logic circuitry configuration at room temperature. Nano-scale logic using magnetic nanostructures could have considerable value for computation and signal processing. Potential advantages of such systems include low-power dissipation and low interconnection demand, thermal stability at room temperature, and high levels of integrability and scalability [24]. 4. Nanowires and nanopillars 4.1. Metal nanowires Arrays of nano metallic and magnetic wires are attractive for their potential applications in radiation and magnetic sensing, high-density magnetic devices, surface enhanced Raman spectroscopy, as well as for fundamental studies of nano-magnetics. The ability to produce highly ordered nanowire arrays cheaply and effectively is important for both purposes. AAO template synthesis using electrodeposition has found to be stable at high temperatures and in organic solvents. It has proved to be a low cost, high yield, and high throughput technique for producing large arrays of nanowires. The primary advantage of this method is ease of material handling. The aluminum substrate remains to supply both mechanical support and electronic contact. The thickness of the oxide layer can be varied freely from very thin to very thick. Various metals such as Ag [25], Fe [26,27], Ni [27,28], and Bi [29] just to name a few have been deposited into the nanochannels by an alternating current (ac) deposition technique. Only ac conditions is found to be effective due to the restrictions arising from the barrier layer of the AAO template and also due to diffusion in the nanopores. An example application of metallic nanowires is uncooled IR detection operating in bolometer mode. Bismuth nanowires are expected to manifest strong quantum size effects due to the large Fermi velocity in Bi and the small transverse dimension. The GMR effect in the magnetic nanowire configuration is expected to exhibit a critical dependence on both the wire diameter and the spacing as well as a great increase in magnitude (possibly even in sign) due to the 1D density of states. Many of the electrodeposition processes have exhibited the so-called ‘‘sky-scraper’’ phenomenon referring to the lack of length uniformity and control. Common to these processes is the use of aqueous solutions, with the exception of a few that used organic solutions [30–32]. In these processes, the positive feedback makes taller wires grow faster and taller. Other drawbacks associated with electrodeposition in aqueous solution include the relatively limited number of elements that can be deposited from aqueous electrolytes, and the need for a conducting substrate. Additionally, the quality of the nanowire arrays may be affected by a number of side reactions, such as oxidation of the metal, and water electrolysis. Eventually, stoppage of wire growth may occur due to the sealing of the AAO template nanopores. By changing the electrolyte of the electodeposition process into a dimethylsulphoxide (DMSO) solution containing metal chloride, the drawbacks associated with aqueous bath can be overcome. 113 114 H. Chik, J.M. Xu / Materials Science and Engineering R 43 (2004) 103–138 Fig. 8. The effect of ac frequency on the filling percentage of the nanopores for Ni nanowire arrays: (a) 0.1 kHz, (b) 0.3 kHz, (c) 0.5 kHz, and (d) 0.75 kHz. For example, NiCl2 and BiCl2 in DMSO was used to grow Ni and Bi nanowires, respectively [33]. With an appropriate choice of the electrodeposition parameters, such as the electolyte concentration, the temperature, and the bath voltage, it is possible to control the growth rate of the nanowire arrays with a remarkable degree of precision and uniformity. In addition, the ac bias parameters, in particular the frequency and waveform affects the filling ratio into the nanopores as shown in Fig. 8. Higher frequencies result in near complete filling of the nanopores as more crystalline nuclei forms resulting in easier deposition of the metal into the nanopores and promoting homogeneous growth of the nanowires. In Fig. 9, the Ni and Bi nanowires were partially exposed by etching back the AAO template allowing easy visualization of the array uniformity. As seen in the image, the nanowires form a highly ordered hexagonal array of uniform spacing and diameter with a good level of uniformity and control in the length. The significance of these results can easily be appreciated in the field of computing technology. Since the early 1990s with the gaining popularity of the personal computer, the storage density of hard disks have increased about 60% per year. In order to ensure good signal-to-noise ratios, each bit on the recording media must be composed of many grains (1000), thus as bit sizes are reduced to increase the areal density, the individual grains are reduced accordingly to a point where thermal stability will become an issue. Perpendicular recording media instead of the traditional longitudinal recording method has attracted great research interest due to the belief that it will offer the largest storage densities. Here, 1 bit corresponds to one single domain particle or a nano-magnet. A highly ordered array of nanowires is a natural choice with each nanowire representing a single nanomagnet. Because of their nano-scale size, anisotropic shape, and spatial separation from each other, each nanowire is a single domain with only two perpendicular magnetization states (i.e. up or down). With a lattice constant of about 50 nm, an areal density of about 300 Gbit/in.2 can be achieved by the hexagonally arranged array. In 1994, Chou et al. demonstrated the ultrahigh density storage using H. Chik, J.M. Xu / Materials Science and Engineering R 43 (2004) 103–138 Fig. 9. Ni nanowires (a) top view and (b) AAO partially etched exposing the nanowires. Bi nanowires (c) after AAO was dissolved, and (d) cross-sectional view in which the bright lines are the nanowires exposed by cracking the AAO template. single domain magnetic nanopillar array by lithography [34]. The 35 nm diameter Ni nanowires with a period of 100 nm were fabricated using advanced electron beam lithography and stamping and electroplating techniques. Using the much less demanding AAO template-assisted nanowire fabrication technique, Nieisch et al. created a similar Ni nanowire array [35]. With a nanowire diameter of 30 nm, the coercivity was 1200 Oe and a squareness of 98% when the external field was applied parallel to the length of the nanowire as shown in Fig. 10(c). Each Ni nanowire is expected to be able to be switched independently to the magnetization of its nearest neighbors and thus be able to store 1 bit of information as shown in the magnetic force microscopy image in Fig. 10(b). The magnetic properties of Fe nanowire arrays prepared by the AAO templating method have also been investigated [27]. An alternative method to grow metallic nanowires involves first removing the barrier layer of the AAO membrane followed by evaporating a metal layer onto one surface of the through-pore template providing a contact for electrodeposition. Various metals can then be deposited into the nanochannels by a simple direct current (dc) deposition technique. The drawback of this technique is the requirement of a freestanding AAO template that must be mechanically robust enough to tolerate manipulation since the membrane is already separated from the supporting bulk aluminum substrate. On the other hand, a thicker template makes it more difficult to fill each nanopore in an uniform fashion. 4.2. Carbon nanotubes Since its discovery in 1991 [36], carbon nanotubes (CNT) has invoked tremendous research interests as they appear to be amongst the most promising materials anticipated to impact future nanotechnology. Their unique structural and electronic properties [37,38], found to vary from metallic 115 116 H. Chik, J.M. Xu / Materials Science and Engineering R 43 (2004) 103–138 Fig. 10. Ni nanowires grown in AAO template from [35]: (a) top view; (b) MFM image showing the nanowires magnetized in the ‘‘up’’ (light) and ‘‘down’’ (dark) states, and (c) SQUID hysteresis loops for Ni nanowires with a diameter of 30 nm and a spacing of 100 nm. H. Chik, J.M. Xu / Materials Science and Engineering R 43 (2004) 103–138 Fig. 11. Process flow for CVD carbon nanotube growth in AAO template: (I) formation of AAO template, (II) electrodeposition of catalyst, (III) CVD growth, and (IV) post growth processing to expose the nanotubes. to semiconducting depending on their lattice symmetry and dimensions, have envisioned for prospective applications include field emission displays, biocompatible sensors, and molecular scale electronic and photonic devices to name just a few. Most of these applications will require a fabrication method capable of producing uniform carbon nanotubes with well-defined and controllable properties. Additionally, the technique employed must be reproducible if any largescale fabrication of carbon nanotubes are envisioned. Efforts to fabricate aligned, isolated carbon nanotubes in an array form have lead to some degrees of success [39–43], arrays of parallel carbon nanotubes with uniform diameters and periodic arrangements have only been achieved with the use of the AAO template [44–48]. The fabrication procedure begins at the same starting point as before, namely after the second anodization step where the AAO template consists of uniform, parallel, hexagonally packed nanochannels following the fabrication procedure previously described. The next step is to electrochemically deposit a small amount of cobalt, nickel, or iron catalyst into the bottom of the template channels as illustrated in the schematic shown in Fig. 11. The ordered array of nanotubes are grown by first reducing the catalysts by heating the cobalt-loaded templates in a tube furnace at 600 8C for 4–5 h under a CO flow at a rate of 100 sccm. The CO flow is then replaced by a mixture of 10% acetylene in nitrogen at the same flow rate for 2 h at 650 8C or higher. The samples are then annealed in nitrogen for 15 h at the same temperature. Fig. 12 shows a SEM image of carbon nanotube arrays which have been ion-milled to remove residual amorphous carbon from the template surface. The nanotubes can then be partially exposed by etching the AAO membrane using a mixture of phosphoric and chromic acid. The resultant nanotubes are uniform in length, parallel to each other, and perpendicular to the template. The diameter of the nanotubes shown is approximately 47 nm which is slightly larger than the original template diameter due to uniform widening of the template nanochannels during the catalyst deposition process. The diameter distribution is only 5% of the mean diameter much narrower than results reported using other methods to synthesis carbon nanotube arrays. The length of the nanotubes is equal to the thickness of the AAO membrane in which they were grown for which in this case was 6 mm. A cross-section SEM image shown in Fig. 13 of the nanotube array partially exposed from the AAO template shows the cobalt catalyst is still at the base of the nanotubes separated from the aluminum substrate. A clearer picture of the cobalt catalyst remaining in the base of a separated nanotube is captured in the TEM image shown in the inset of the figure. The use of CNTs for large scale nano-electronics has hinged on being able to position the CNTs selectively and to integrate them in ultra high densities. With the carbon nanotubes now positioned in the periodically ordered AAO template and densities approaching 1011 order of magnitude elements per square centimeter, this obstacle appears to have been lowered. Choi et al. presented a 20 nm in diameter, 40 nm in pitch tera-level density CNT transistor grown in the AAO templates [49]. E-beam 117 118 H. Chik, J.M. Xu / Materials Science and Engineering R 43 (2004) 103–138 Fig. 12. Carbon nanotubes grown in AAO template (a) oblique angle view with nanotubes exposed and (b) top view showing 47 nm diameter nanotubes. lithography was used to pattern the AAO membrane before nanotube synthesis to selectively grow CNTs in certain nanopores and after nanotube synthesis to define the gate, drain, and source contacts of the transistor. Each CNT is electrically attached by rows of metal contacts on the top and bottom surfaces forming a matrix of electrodes. To address an individual vertical CNT, a bias must be applied between the corresponding row of electrode on the top and bottom surfaces. In this configuration, each individual CNT is uniquely addressable as shown in Fig. 14. Taking advantage of the unique properties of the CNTs such as high thermal power dissipation, high electrical conductivity, and ultra small power consumption, it is conceivable that tera-level density CNTs will play a role in the realization of next generation nano-electronics. The synthesis of connections between two or more different carbon nanotubes is an important step in the development of carbon nanotube based electronic devices and circuits. However, this is difficult to achieve using conventional methods to grow carbon nanotubes because the straight tube structure cannot be controllably altered along its length. Various ideas for post-growth modifications H. Chik, J.M. Xu / Materials Science and Engineering R 43 (2004) 103–138 Fig. 13. Cross-section SEM image showing the presence of the cobalt catalyst sitting at the base of the carbon nanotubes. The inset is a TEM image of a single nanotube. have been suggested [50], but these have been hard to implement and are prone to defects. The AAO template method to grow uniform, highly ordered straight carbon nanotubes as described above, can be extended to grow uniform, highly ordered Y-junction carbon nanotubes [51]. The growth of the Y-junction CNTs follows the same recipe as growing straight CNTs of pyrolysis of acetylene with cobalt catalysis. The alteration comes in the preparation of the AAO template. Because the pore diameter is proportional to the anodization voltage, reducing the voltage by a factor of 21/2 results in twice as many nanopores appearing in order to maintain the of the template, and nearly all nanopores branched into two smaller diameter nanopores. Thus, by switching the voltage during anodization, a larger nanopore (stem) will gradually evolve into two smaller diameter nanopores (branches) as shown in the inset of Fig. 15 where the resulting template consists of parallel Y-branched nanopores with stems 40 nm in diameter and branches 28 nm in diameter. In the crosssection SEM image, the arrow indicates the transition between the stems (upper 3 mm of template) Fig. 14. Carbon nanotubes grown in patterned AAO nanopores after [49]: (a) oblique angle view of exposed nanotubes, (b) schematic of the transistor architecture, and (c) top view of an array of transistors with each at the cross point of a drain and a gate electrode. 119 120 H. Chik, J.M. Xu / Materials Science and Engineering R 43 (2004) 103–138 Fig. 15. Cross-section view of a Y-junction AAO template with the arrow pointing to the straight to Y-junction CNT growth transition. The inset depicts a clear image of the transition region. and the branches (lower 2 mm of template). A TEM image in Fig. 16 shows the Y-junction CNT after being removed from the template. In this case, the stems are 90 nm in diameter while the branches are 50 nm in diameter. Electronic transport measurements show that the Y-junctions act as semiconductor heterojunctions as their behavior can be explained simply by considering the change in bandgap across the junction caused by joining together different diameter nanotubes [52]. This structural configuration naturally leads to a three-terminal nano-scale transistor by applying different voltages to each of the Y-junction arms. This integrated transistor function will provide the nano-electronics community with a new base material for the development of molecular-scale electronic devices. With the Y-junction CNTs still in the AAO template and each one behaving as a transistor, logic gates can be formed by selectively connecting two or more nanotubes in parallel from the array as illustrated schematically in Fig. 17. 4.3. Semiconductor nanopillars Instead of growing nanostructures by electrochemical deposition as for metallic nanowires or by pyrolysis for carbon nanotubes, in this section, the nanostructures are fabricated by etching into existing material and using the AAO template as an etching mask in the traditional sense. In standard lithography, to etch a pillar from a bulk substrate, a mask, usually formed from metal or silicon dioxide/nitride, is deposited to protect desired areas from the etching chemicals. Everywhere else left unprotected, the material is etched away leaving the a pillar-like structure protruding from the substrate. Here a similar approach is taken to fabricate highly ordered nanopillars or superlattice of quantum dots described in the next section. The fabrication procedure begins with forming a perfect hexagonal array of metal nanodots onto the substrate, as described earlier, where the nanopillars are to be formed. Then a deep reactive ion etching (RIE) process is employed to obtain high aspect ratio semiconductor nanopillars using the H. Chik, J.M. Xu / Materials Science and Engineering R 43 (2004) 103–138 Fig. 16. Y-junction CNTs: (a) oblique angle view with the CNTs still in the AAO template and (b) TEM image of the Yjunction region. metal nanodots as the etching mask. Fig. 18 shows the oblique SEM views of GaN and GaAs nanowire arrays after their respective etches using the metal nanodot array as a mask [53]. An aspect ratio of 1:10 was achieved with a nearly vertical etch profile. The dry etching conditions are listed in Table 2. 4.4. Quantum dots The idea to further confine carriers to a greater degree and ultimately reducing the dimensionality to zero, a quantum dot, has been sought after in the development of electro-optic 121 122 H. Chik, J.M. Xu / Materials Science and Engineering R 43 (2004) 103–138 Fig. 17. Schematic of example logic gates formed by selectively connecting two or more Y-junction CNTs, which are individually a transistor, in parallel. devices. When the quantum dots act as the active layer of a semiconductor laser, theoretically the device offers low threshold current density, good temperature characteristics, and broad wavelength tunability. To obtain maximum quantum effect, dots must be of uniform size, shape, and composition. The most commonly used method to fabricate quantum dots so far is the selfassembled epitaxial growth based on strain-induced Stranski-Kranstanov (SK) mode growth [54–56]. Fig. 18. Oblique angle views of (a) GaN nanopillars and (b) GaAs nanopillars. H. Chik, J.M. Xu / Materials Science and Engineering R 43 (2004) 103–138 123 Table 2 Typical dry etching conditions for nanopillar formation Substrate Gas Flow rate (sccm) Pressure (mTorr) Power (W) GaAs GaN Nb Si BCl3 Cl2 CF4 þ O2 BCl3 þ Cl2 20 60 42 þ 2 5 þ 10 15 80 50 50 100 200 100 100 It is, however, material specific as the growth mode relies on the strain between the quantum dot and the substrate material such as InAs/GaAs, thus cannot be used in the growth of homoepitaxy and closely lattice matched heterostructures such as AlGaAs/GaAs. Also, the SK growth mode still lacks the uniformity, the ordering, and the packing density achievable in the nanopore template approach. One alternative strategy capable of forming complex structured QD arrays is to start with epitaxially grown multi-layered structures such as multi-quantum wells, PN and heterojunction structures, followed by the use of the template-assisted method of fabricating high aspect ratio nanopillar array as described earlier. One major advantage of this method for QD fabrication over self-assembly or self-assembly based strain engineering is that it allows for accurate multi-activelayer stacking. The other advantages of this method over self-assembly include the uniformity and the accurate controllability of feature size and position. A schematic is shown in Fig. 19 to illustrate this idea where a multi-quantum well wafer is patterned into three vertically stacked lateral superlattices of quantum dots, which are quantum mechanically coupled. Moreover, each column of coupled quantum dots can be contacted naturally on the top with self-aligned metal dots. An anticipated problem of this approach is the rather large surface recombination usually occurring on un-passivated etched surfaces. A solution might be in epitaxial regrowth. This problem seems not as severe in such material systems as GaN where the free-surface recombination velocity is low as demonstrated in [57]. A comparison of templateassisted etched 50 nm nanopillars in InGaN/GaN multi-quantum well to an unprocessed wafer revealed similar optical properties suggesting that surface recombination at the etch exposed vertical walls of the nanopillars is modest at best. When compared to e-beam written 100 nm nanopillars, the two nanopillars revealed robust photoluminescence (PL) efficiencies, not impaired by the very large surface to volume ratio and even exceeding those of an unpatterned quantum well wafer when taken into account the actual areal filling factors. This has presumably benefited from the higher photon escape probability due to the post-like texture of the light emitting medium. Fig. 19. Schematic of transforming an epitaxially grown quantum well structure to a quantum dot structure using the AAO membrane as a mask. 124 H. Chik, J.M. Xu / Materials Science and Engineering R 43 (2004) 103–138 A novel material system, InGaAsN:Sb is being explored in this framework as well for possibly extending the GaAs based material system into the infrared optical telecommunication wavelengths. This potentially important material only proposed in 1996 has developed to a point where good quantum well materials can be grown. There have been a few demonstrations of its potential as a optical source. By using the AAO templating technique as described above, explorations into quantum dots can take place immediately and would not have to wait for developments relying on self-assembly techniques that would take considerable amount of efforts in optimizing the growth conditions. A study of the optical properties of InGaAsN:Sb/GaAs QDs fabricated through the nanopore templating and etching technique has already been investigated [58]. The MBE grown quantum well structure was first patterned with Ni nanodots to act as the mask for the subsequent RIE in a BCl3 environment. The resultant structure is a hexagonal, periodic array of 55 nm diameter, 6.7 nm thick InGaAsN:Sb quantum dots sandwiched between GaAs layers. Unlike all other studies normally done at low temperatures, room temperature photoluminescence was demonstrated in the etched quantum dot array with free exposed surface and found to exceed as-grown InGaAsN:Sb/GaAs quantum wells by several times. Stronger hole localization (in the x–y plane) in the dots appears to be the key to the observed improvement. These findings might be particularly important for the fabrication of the improved long wavelength room temperature operating 3D light emitting electronic devices. The strategy adopted in the previous references represents an effective way to fabricate highly ordered, multi-layers of quantum dots perfectly stacked on top of each other. It also presents a simple method to study nanopillar heterojunctions since the heterojunction interface is of high quality proven with many years of refined epitaxial growth techniques. It is more attractive than trying to grow good material in the nano-scale sizes and hoping for good heterojunctions. Although Mei et al. [59] did realize MBE grown highly ordered InGaAs/GaAs and GaAs/AlGaAs quantum dot arrays using the AAO template as a shadow mask, it is more like a point contact array on a continuum in terms of heterojunction. A viable approach to form QDs embedded in a wider bandgap surrounding is to first form nanocavities by the template-assisted etch followed by epitaxial regrowth in molecular-bean epitaxy (MBE) and metalorganic chemical vapor deposition (MOCVD) processes [60,61]. It was shown that InAs quantum dots can be selectively grown at the bottom of honeycomb hollows formed by anodization of GaAs substrate. The average size of the InAs quantum dots and its variation were considerably affected by the regularity of the hollows [61]. Not surprisingly, the honeycomb hollows of anodized GaAs are of less uniformity and ordering than that of the AAO template. The size of the hollows is of the order of 200 nm. The AAO template approach of fabricating semiconductor anti-dot array offers a simple and effective way for optimizing the control of the size and density of QDs on a pre-patterned substrate through the control of the diameter, spacing, and depth of the pre-patterning. Having semiconductor nanopillars either with homogeneous or heterogeneous material fabricated by two distinctive methods, etching or growth, offer an opportunity to study the effects of surface states on the properties of semiconductor nanostructures. In the conventional material systems, bulk states dominate the overall properties. When it comes to nanostructures with confined dimensions, such as those realized by this template method, the surface to volume ratio is so high, surface layer properties are no longer of secondary importance. When created by dry etching, there are plenty of dangling bonds associated with and therefore depletion layer in the surface region of atoms. When formed by growth, the surface atoms assemble in a way to try to minimize the total energy by forming self-closed orbitals (bonds) thereby deforming or restructuring the lattice. Thus, with the same material of similar confined dimensions but fabricated differently, we are permitted H. Chik, J.M. Xu / Materials Science and Engineering R 43 (2004) 103–138 through the manipulation of surface states to create and study new properties in the nanostructures, and in their interfaces with other materials. 4.5. Vapor–liquid–solid growth method Porous anodic aluminum oxides are particularly useful for optical studies of the nanoparticle structures prepared within their pores because the host oxide is transparent over much of the visible and infrared spectral regions. Furthermore, polarization dependent optical properties of nanowires can be determined due to the parallel orientation of the cylindrical nanopores. Ordered semiconductor ZnO nanowire arrays have been grown in the AAO template along the nanochannels [62]. After electrodeposition of Zn and with the metal sitting at the bottom of the AAO template, the sample was then heated in air at 300 8C for 35 h transforming the metal into polycrystalline ZnO of various orientations resembling standard powder diffraction patterns of ZnO. The diameters of the nanowires ranged from 15 to 90 nm dependent on the nanopore size and the height determined by the height of the electrodeposited Zn. For many applications, the nanowire needs to extend beyond the template surface or be completely removed from the AAO membrane. With the electrodeposition and oxidation method previously described, this cannot be done. Recently, there has been more interest in a technique first proposed in the 1960s, namely, the vapor–liquid–solid (VLS) growth method [63]. Here, metal nanodots are used as catalysts promoting nucleation at each site forming nanowires. The VLS reaction has been used to obtain Si [64,65], InP [66], CdS [5], and GaN [67–69] nanowires to name a few. Extending the VSL growth method by starting with highly ordered metal nanodot arrays, a large number of free standing highly ordered and uniform semiconductor nanowire arrays can be synthesized with high aspect ratios covering a large area. ZnO nanowires have recently been grown using this growth method with a high degree of ordering by using the catalytic Au nanodots as the nucleation sites [70]. ZnO is of much interest as it is a semiconductor that has the potential for application in a wide range of fields due to its unique properties. The material has a direct bandgap of 3.37 eV at room temperature and its larger exciton binding energy of 60 meV and higher optical gain, when compared to its GaN counterpart, leading to demonstrations of room temperature lasing from single nanorods [71]. Taking advantage of its strong UV absorption, ZnO is seen as a promising material for solar cells even in its bulk form, but with a packing density of 1011 cm2 vertically aligned nanorods dramatically increasing the surface to volume ratio, that vision can only be enhanced. Besides its optical applications, ZnO based surface acoustic wave devices have been shown, exploiting its piezoelectric property. Bulk ZnO has been used as a gas sensor material relying on the interaction of the gas molecule and the surface of the ZnO. Again, enhanced device sensitivity can be envisioned with increased surface to volume from arrays of nanorods. However, while many different routes to synthesize ZnO nanowires have been undertaken including physical vapor deposition [72], vapor-phase transport [73–75], and chemical vapor deposition [76], high fabrication costs, reduced crystallinity, wool-like geometry along with low control over the nucleation site and size of the nanorods severely limit the development of ZnO nanowires into useful electronic, optical, and mechanical nanodevices. Selected catalytic vaporphase transport growth methods [73], template-assisted methods [62], catalysis-driven MBE growth methods [77], and metalorganic vapor-phase epitaxy (MOVPE) growth methods [78] have produced site-specific nucleation of ZnO. However, for nanodevice integration, along with site-specific nucleation is the need for the ability to place the nucleation site. By controlling the spatial arrangement of the catalysts. Direct size and placement control of ZnO nanowires can be achieved by using the AAO template to create an array of Au nanodots (catalysts). The diameter of the 125 126 H. Chik, J.M. Xu / Materials Science and Engineering R 43 (2004) 103–138 nanowire is determined by the diameter of the catalyst, and thus the AAO templating method is an ideal candidate as the diameter of the nanopores can be altered by changing electrochemical solution used in the anodization process. By reducing the variations in the physical properties associated with different diameters and randomness in their positioning further increasing the ease and flexibility in engineering nanodevice characteristics. Starting with Au nanodots 50 nm in diameter and spaced 110 nm apart center-to-center on the GaN surface after the AAO template has been removed, the patterned GaN substrate was placed onto a ceramic boat downstream from the ZnAs2 source supplying zinc in a horizontal tube furnace. In the sample shown in Fig. 20, a growth time of 20 min produced nanorods of 400 nm in average length. The average diameter of the resultant nanorods is 60 nm. The nanorods are vertically aligned with respect to the surface of the GaN and orderly spaced in the hexagonal pattern defined the AAO template deposition of the Au catalysts. As shown in Fig. 20, the Au catalyst remains at the top of each ZnO nanorod indicative of the vapor–liquid–solid growth process [63]. First, formation of an eutectic alloy droplet occurs at each catalytic site, followed by the nucleation and growth of the solid ZnO nanorod due to the supersaturation of the liquid droplets. Incremental growth of the nanorod takes place at the droplet Fig. 20. ZnO nanowires grown perpendicularly to the GaN substrate: (a) top view showing hexagonal shaped nanowires with Au catalysts remaining atop and (b) oblique angle view. H. Chik, J.M. Xu / Materials Science and Engineering R 43 (2004) 103–138 interface constantly pushing the catalyst upwards. Thus, this growth method inherently provides sitespecific nucleation at each Au catalytic site. The presence of a metal catalyst provides a natural contact on one end of the nanorod, which can be beneficial in certain applications where making contacts to the nanorod is necessary. Since GaN and ZnO share a common crystal structure with a lattice mismatch of less than 0.08%, the nanorods grown on GaN are hexagonally faced strongly suggesting that they are of hexagonal wurzite crystal structure with peaks in the X-ray diffraction (XRD) pattern indexed to bulk ZnO. It suggests c-axis orientation growth or perpendicular to the surface of the GaN. The band alignment between GaN and ZnO is such that a type-II heterojunction is formed at the interface and the associated charge transfer provides effective doping. Photoluminescence spectroscopy on ZnO nanorods dispersed in solutions showed strong emission in the ultraviolet region with a peak at 377 nm and a FWHM of 20 nm attributed to the exciton peak. A secondary broader band in the visible green region around 511 nm also appeared in the spectra attributed to the recombination of photogenerated holes with the singly ionized oxygen vacancies in the ZnO crystal structure [79]. 4.6. Other in-template growth methods In recent years, nanostructured electrode materials have attracted attention since the capacity of the electrode is critically affected by its morphology. Better rate capabilities can be obtained due to the reduction in the distance over which Liþ ions must diffuse in the nanostructured electrodes of rechargeable lithium-ion batteries. In addition, the surface to volume ratio of the nanopillar electrodes is much larger than conventional unstructured electrodes leading to smaller current densities for a given current during charging and discharging. Sol–gel chemistry is a technique that has been employed to fabricate LiNiO2 [80], LiMn2O4 [81], LiCoO2 [82], and LiNi0.5Co0.5O2 [83] in-template nanowires. The growth method typically involves the hydrolysis of a solution of a precursor molecule to obtain a suspension of colloidal particles. This is the sol part of the equation. The gel is composed of aggregated sol particles thermally treated to yield the desired material. To obtain in-template nanowires, the AAO template is dipped into the sol allowing the solution to diffuse into the nanochannels. After a set length of time, the template is removed from the sol and heated at elevated temperatures. Fig. 21 shows SEM images of LiMn2O4 nanowires. Highly ordered zirconia nanowire arrays have also been demonstrated by the AAO template method using sol–gels [84]. Cheng et al. synthesized in-template GaN nanowires through a gas-phase reaction of Ga2O vapor with flowing NH3. While Yu et al. fabricated in-template poly(p-phenylene) PPP nanowire arrays in also a gas-phase reaction of benzene, aluminum chloride anhydrous, and cupric chloride anhydrous [85]. PPP is an interesting material because of its capability of being transformed from an electrical insulator to an electrical conductor with applications in light-weight rechargeable batteries and blue emitting devices. Clearly from the numerous examples, the AAO templating method can be seen as an extremely versatile tool in the fabrication of highly ordered, densely packed nanowires and nanopillars of various materials. 5. Nanopores and anti-dot arrays The versatility of the non-lithographic AAO template approach allows it to be extended into fabricating superlattice nanopores. Much of the attention in research has gone into nanowires, 127 128 H. Chik, J.M. Xu / Materials Science and Engineering R 43 (2004) 103–138 Fig. 21. LiMn2O4 nanowires fabricated using sol–gel techniques from [81]: (a) magnified cross-section view and (b) crosssection view showing length of nanowire about 30 mm. nanopillars, and nanodots. This natural course of progression from bulk materials to nanowires to nanodots in an attempt to exploit the quantum properties of small sizes is indeed fascinating and well deserving of the attention, however, work with ‘‘empty’’ spaces is proving to be just as interesting as new physics and phenomenons are being uncovered. In the sections to follow, some of the novel physics utilizing nanopores will be presented. The fabrication of nanopores is a relatively simple process. In a ‘‘positive’’ transfer, the nanopore array pattern is replicated conveniently through etching, chemically and/or physically in the substrate resulting in lateral superlattices of what are often referred to as ‘‘anti-dots’’ (pores). One procedure we often follow employs the AAO nanopore array membrane as an etch mask. Briefly, it goes like this: After the template has been formed and the barrier layer removed as described in previous sections, the highly ordered AAO nanopore film is placed onto the desired substrate. Dry etch methods, such as plasma etching, ion milling and reactive ion etching, are H. Chik, J.M. Xu / Materials Science and Engineering R 43 (2004) 103–138 Fig. 22. GaAs nanopore array from [86]: (a) cross-sectional view and (b) plot shows the 10:1 aspect ratio of the nanopore depth to diameter greatly reduces the etch rates inside the nanopores. used for transferring the pattern to the substrate because of their better directionality over wet etching. Nakao et al. were amongst the first to report the formation of nanopore arrays in semiconductors using the AAO templating method in 1998 [86]. GaAs and InP nanopore arrays were formed using a reactive beam etching technique with Br2–N2 gases at elevated substrate temperatures. Nanopores of up to 1 mm in depth were etched, however, as noted by the authors, the holes at this depth have partly collapsed. Fig. 22(a) shows the cross-section SEM image of a 80 nm diameter and a 500 nm deep GaAs nanopore array. At these high aspect ratio approaching 10:1 (depth to width), etching rates inside the pores are dramatically reduced to the tune of one order of magnitude slower as shown in the graph in Fig. 22(b). Typically thickness used are around 500 nm still leaving an aspect ratio of 129 130 H. Chik, J.M. Xu / Materials Science and Engineering R 43 (2004) 103–138 10:1 with respect to the width of each nanochannel. When one takes in account the 0.5 mm AAO template which is being etched, albeit at a much slower etch rate, the aspect ratio at the end of nanopore etching process is almost 20:1. Thus, an argument is made for reducing the thickness of the AAO template to as thin as possible if deep nanopores are desired with it still being possible to physically handle. Micro-loading effects were also seen as 60 nm diameter pores were 10% shallower in depth than 80 nm diameter pores. The atomic force microscope (AFM) images in Fig. 23 show a nanopore array on GaN with a depth of about 120 nm, a mean pore diameter of approximately 40 nm and a period of 100 nm by Fig. 23. AFM images of a nanopore array in GaN. H. Chik, J.M. Xu / Materials Science and Engineering R 43 (2004) 103–138 RIE. The typical nanopore etching conditions for different semiconductors such as silicon [87] are the same as for etching nanopillars listed in Table 2. Guo et al. also employed reactive ion etching techniques using a combination of CH4 and H2 gases to fabricate 60 nm nanohole channels in ZnTe [88]. In transferring the AAO nanopore pattern onto the substrate, reactive ion etching is typically used due to its directive etching nature, its smooth etched surface morphology, high etch rates, and vertical sidewalls. In this process, any gap between the template and the substrate should be minimized to ideally a direct contact so as to prevent unwanted etch along the gap. To circumvent the challenges in placing the ultra-thin AAO film onto the receiving substrate, an Al film can be sputtered or evaporated onto the substrate as done by Crouse et al. [89]. After evaporating 2 mm of Al onto a conducting Si substrate, anodization using similar recipes proceeded. One limitation to this process is the substrate must be conducting as the anodization procedure requires the voltage drop on the Al surface. After anodization, the AAO film was thinned from 2 to 300 nm by a 1 h argon-ion milling procedure to make the subsequent RIE pattern transfer to Si substrate easier. Fig. 24(a) shows the AAO layer on the Si substrate after anodization, and Fig. 24(b) the result of a 1 min RIE into Si with the ordered AAO nanopore film still attached to the substrate. Fig. 24. Anodization performed with Al film on Si from [89]: (a) cross-sectional view of highly ordered AAO nanochannels and (b) after nanopore pattern transfer. 131 132 H. Chik, J.M. Xu / Materials Science and Engineering R 43 (2004) 103–138 5.1. Optical properties and phenomenons Arrays of nanopores with a high degree of uniformity and ordering have lead to new effects just as important and interesting in the collective excitation or relaxation modes and in the near-field (or sub-wavelength) coupling regime. The systems in such collective modes can manifest behaviors deviating fundamentally from the classic processes such as diffraction limits and photoluminescence [90]. Ebbesen et al. demonstrated that the zero-order transmission of light (the incident and detected light are collinear) through sub-wavelength hole arrays made in a metal film can be orders of magnitude larger than is expected from classical aperture theory [91]. Sharp peaks are observed in the transmission spectra at wavelengths as large as ten times the diameter of the cylindrical nanopores. From classical theory, the transmission of a sub-wavelength aperture is proportional to the fourth power of the ratio of its diameter and wavelength of light. Thus, one would expect transmission in the order of 1% efficiency instead of the observed ‘‘apparent’’ 130% when normalized to the area covered by holes [92]. This extraordinary phenomenon can be used in a number of applications such as sub-wavelength photolithography, near-field microscopy, molecular imaging, and data storage. However, the underlying physical mechanism has not yet been fully understood despite some elucidations based on numerical models [93]. The few efforts to date all point to the central role played by surface plasmons and their collective excitations by and interactions with photons. Although the experiments have been fewer than desired, they are very exciting for they represent a new opportunity in realizing the long-sought coherent and collective interactions of electrons with a radiation field. Progress to date on this new frontier has been confined to samples made by e-beam lithography or focused ion-beam milling, but more rapid progress can certainly be made with strategies readily implementable with the AAO nanopore array such as simply coating the membrane by evaporating metal film of various thickness and materials. Although the use of AAO templates have not been demonstrated for this application, it is not difficult to envision its place in this field of work. Recently, metal hole arrays were fabricated by a two-step molding process using the AAO template as the medium for the high aspect ratio holes. Instead of relying on the two-step anodization process to form the ordered nanopore pattern, an e-beam written SiC mold was used to imprint the Al replacing the first anodization step [94]. With the Al pretextured with shallow concave imprints, the standard anodization procedure followed creating highly ordered nanopores with an aspect ratio of 7. A Ni metal film was then evaporated onto the nanopore surface with the results shown in Fig. 25. The depth of the nanopores is 2.5 mm with a pore diameter of 350 nm and a pore spacing of 500 nm. Nanopatterned surfaces could exhibit very low reflectivity over a broad bandwidth and a very large viewing field, if the nanopores or nanopillars are etched deep enough into the surface. Conceptually, the large aspect ratio and sub-wavelength texture create an effective gradual index change from that of air at the top to that of the substrate at the bottom. The weak but numerous distributed scatterings by the sub-wavelength features also gives rise to diffusive optical transport, adding to the effective grading of the index. Theoretical and experimental evidence supporting this expectation were first obtained recently in silicon where a reflectivity as low as 1.6% was measured over a range of 300–800 nm [95]. The reflectivity of a polished silicon wafer over the same wavelength range is about 35%. The non-lithographic template fabrication approach is uniquely advantageous for patterning curved surfaces for experimental demonstration and optimization of the expected broadband anti-reflection characteristics, and for enabling novel coherent electron transport studies. This method is also readily scalable to large areas. Silicon-based photonics has been much sought after with great anticipation of enabling direct integration with its fully developed electronic counterpart. Silicon photodetection can be readily H. Chik, J.M. Xu / Materials Science and Engineering R 43 (2004) 103–138 Fig. 25. Ni film with highly ordered nanopores produced from e-beam written SiC mold, imprinting, followed by anodization: (a) top view and (b) cross-sectional view from [94]. performed, however, photon emission from bulk silicon is approximately 1% efficient at best due to the fact it is an indirect bandgap semiconductor. By terminating the continuum of the silicon crystal with interfaces nanometers apart, one can both break the crystal symmetry and introduce the quantum confinement, and thereby, with the former, alter the dispersion relation, and with the latter, enhance the exciton and optical oscillator strength. A quantum anti-dot configuration, where periodic nanopores are created in a thin layer of silicon, is electrically connected with constrictions that are narrow (quantum) enabling possible cascade emission and amplification. The anti-dot configuration also helps with the desire of minimizing re-absorption enabling the possibility of a silicon laser. On another front where the creation of nanopore array on semiconductor is followed by subsequent epitaxial growth, positive but still preliminary results have been obtained. Exploratory studies of nano-heteroepitaxial growth of GaN films on highly ordered nanoporous Si(1 1 1) substrates show that a multi-fold increase in photoluminescence intensity can be obtained. The observed improved quality suggests that the uniformly nanopatterned interface structure, as expected, does offer an advantage for releasing stress due to lattice and thermal expansion differences. The nanopore array surface with the pore diameter of 60 nm and periodicity of 110 nm exhibits significant benefits for emissivity, film growth, and the relaxation of misfit and thermal strain in the film. Peak shifts in photoluminescence and Raman spectroscopy indicate that the material grown on nanopores is more relaxed than films grown on flat Si(1 1 1) substrates. The effects of nanopore topography on the nucleation of GaN films offer a potential path to significant improvement of III-nitride heteroepitaxy for device applications [96]. 133 134 H. Chik, J.M. Xu / Materials Science and Engineering R 43 (2004) 103–138 5.2. Superconducting nanomesh This simple approach of using the highly ordered AAO template to fabricating nanomeshes has already led to significant advances in vortex physics of normal superconductors [97]. In a recent experiment, AAO membrane was covered with a 100 nm film of Nb deposited by magnetron sputtering followed by a 10 nm thick Ag capping layer as shown in Fig. 26(a). The SEM image shows the highly ordered nanopore pattern in the cleaved AAO membrane after Nb and Ag layers have been deposited. Since the sputtered Nb and Ag layers deposit onto the walls of the AAO nanopores, the pore opening diameter is reduced to 45 nm. The pore spacing is left unchanged at 101 nm. The pore density in these arrays is almost two orders of magnitude greater than in typical lithographically prepared micron-sized hole arrays. Magnetization and magneto-transport Fig. 26. (a) Oblique angle view of an AAO membrane covered with 100 nm of Nb capped with 10 nm of Ag. The white line shows a grain boundary between hexagonal nanopore patterns of different orientation and (b) magnetic moment of the Nb-AAO array for a perpendicular applied field. The matching fields are denoted H1, H2, and H3. H. Chik, J.M. Xu / Materials Science and Engineering R 43 (2004) 103–138 measurements reveal effects not seen in the lithographically produced hole arrays as the higher density non-lithographically produced hole arrays puts the templated vortex array into the strongly interacting limit where vortex–vortex interactions reinforce the natural pinning of the template. Revealed effects include: Confinement effects where the dimensional crossover from 2D superconductivity behavior to 1D behavior are seen above 6 K. Little-Parks oscillations of the upper critical field are seen above 6 K. The presence of strong pinning at low temperatures. The matching fields and strong pinning reveal pronounced stepwise variation of the critical current at multiples of the fundamental matching field and extends to much higher fields, 7.5 kG for the third matching field, whereas the matching field effects decay above a few hundred Oe; see Fig. 26(b). Pinning is enhanced by two orders of magnitude over that in continuous Nb films. The strong pinning enables even low pinning superconductors to carry a high critical current Viewing this work from a broader perspective, one can see that similar strong collective behaviors arising from coherent couplings of electronic and optical modes induced and modulated by periodic distributed near-field coupling can also be expected in non-superconducting media. 6. Summary and future prospects We have attempted in this review to summarize the progress of a non-lithographic technique using the self-organized, highly ordered AAO membrane as a template to fabricate various nanometric structures and briefly present their immediate contributions to nanotechnology in a field still in its infancy. The AAO membrane itself determines the uniformity, packing density, and size of the nanometric superlattices made by using this approach. By varying the anodization conditions, the diameter of the nanopores of the AAO templates can be altered between 20 and 120 nm. The packing density can reach the order of 1012/cm2 covering an area that is readily scalable. The fact that material systems as different as metals, semiconductors, and carbon nanotubes can be treated with the same ease and the fact that structural forms as different as dots, tubes, pillars, anti-dots (nanopore meshes) can be fabricated with the same base technology attests to the generality of this nano-fabrication approach. The flexibility of using a variety of materials, the accurate control over fabrication process, and the command over nanopore template features give us the freedom of engineering various physical properties determined by the shape, size, composition, and doping of the nanostructures as well as many new properties enabled by their couplings. The novel nanometric superlattice platform realized by this unique nano-fabrication approach can powerfully enable a broad range of applications in electronics, optics, mechanics, and bio-technologies. Some of these are extraordinary properties and functions not intrinsic to the individual nano-elements but only arise from the collective behaviors of the large ensemble of periodically coupled and uniform nanostructures due to the near-field coupling and sub-wavelength spacing. By manipulating the geometry of otherwise conventional materials into within the mesoscopic length scales comparable to the mean free lengths, exciton radius, or Fermi wavelength, we can realize unconventional physical properties due to the size effects as well as due to surface reconstructions. When combined with compositional changes on the same length scales, nano-scale engineering offers us a truly new capability in science and technology. 135 136 H. Chik, J.M. Xu / Materials Science and Engineering R 43 (2004) 103–138 Acknowledgements This paper covers a large set of results and findings from a number of projects supported by AFOSR, AF Labs, CIAR, DARPA, Motorola, NSF, Nortel, and ONR. 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