Magnetron sputter coating source for both magnetic and non magnetic target materials

A novel magnetron sputter coating source is disclosed in which magnetic sputter targets containing relatively large inventories of usable material may be employed. This coating source may also be used efficiently and effectively with sputter target materials having properties which range from nonmagnetic to highly ferromagnetic. Use of an electromagnetic coil with a widely adjustable energizing current, rather than permanent magnets, allows a wide range of magnetic properties to be accommodated. Electrical impedance of the glow discharge is readily controlled using the current flow through the electromagnetic coil, allowing, for example, operation at desired values of voltage and current throughout the life of the sputter target. In addition, a momentary increase in electromagnet coil current can be used to achieve ignition of the glow discharge at a desired sputter gas operating pressure which is below the sputter gas pressure at which the glow discharge can normally be readily ignited. Also, use of the electromagnetic coil permits an easy conversion of the magnetron sputter coating source to a nonmagnetic diode apparatus. The use of a Hall probe positioned adjacent and below the sputter target near the region of maximum erosion is disclosed. The Hall probe voltage, which is proportional to the magnetic field intensity at the Hall probe position, may be measured throughout sputter target life to provide an independent means of assessing the approach to end of useful life. A novel sputter target cooling means is disclosed in which a water chamber below the sputter target is divided into inlet and outlet portions by a septum. The flow of water through a narrow gap between the septum and the sputter target leads to highly effective heat transfer, which is also highly uniform along the peripheral path of intense heating of the sputter target.

FIELD OF THE INVENTION 
This invention is in the field of vacuum coating apparatus and particularly 
relates to coating with both magnetic and nonmagnetic materials using 
magnetron sputter coating sources. 
BACKGROUND OF THE INVENTION 
Vacuum deposition of coatings using cathode sputtering induced by glow 
discharges is currently in widespread use. Sputter coating sources include 
cathode and anode structures, and are operated in an evacuated chamber 
backfilled with a sputter gas (typically argon at subatmospheric 
pressure). Positive ions formed in the space between anode and cathode 
impact a target located on the cathode surface, ejecting (by sputtering) 
atoms of target material from the surface and near subsurface atomic 
layers of the target. These sputtered atoms deposit on workpieces or 
substrates placed generally in line of sight of the target. Magnetron 
sputter coating sources employ magnetic fields crossed with electric 
fields in the vicinity of the target. The use of such magnetic fields can 
enhance glow discharge intensities and the attendant sputtering rates, 
extend operation to lower sputter gas pressures, confine the flow 
discharge to the neighborhood of the electrodes, and reduce electron 
bombardment of the substrates. 
One type of magnetron sputter coating source in commercial use employs a 
nonmagnetic annular sputter target (cathode) of a generally inverted 
conical configuration surrounding an axially symmetric central anode. One 
example of such a sputter coating source may be found described in U.S. 
Pat. No. 4,100,055, issued July 11, 1978 to Robert M. Rainey and entitled 
"Target Profile for Sputtering Apparatus" and assigned to the assignee of 
the present invention. Magnetron sputter coating sources of the type just 
mentioned have been used extensively and effectively in important 
semiconductor wafer coating applications. In most cases, the materials 
being deposited are nonmagnetic, such as aluminum and its alloys, etc. In 
some cases, however, it has been desired to use the same sputter coating 
source to dispense such magnetic materials as iron, nickel, 
iron-nickel-alloys, etc., as well as the nonmagnetic materials for which 
the sputter coating source was initially designed. More recently, a need 
has emerged for coating magnetic disk substrates with multiple layers, at 
least one of which is of magnetic material. Magnetic disks are now vitally 
important in computer memory applications. 
Simply replacing a nonmagnetic sputter target with a magnetic one of the 
same generally inverted conical configuration in the magnetron sputter 
coating source referred to above causes most of the magnetic field to be 
shunted through the magnetic target. This results in magnetic field 
intensities above the target which are too low to allow the desired 
magnetic enhancement of the glow discharge to take place. 
In order to avoid excessive reduction in magnetic field intensities above 
the target, annular magnetic sputter targets of a generally L-shaped 
profile have been developed for use in the above-described sputter coating 
source. One such L-shaped magnetic sputter target is described in U.S. 
Pat. No. 4,060,470, issued Nov. 29, 1977 to Peter J. Clarke and entitled 
"Sputtering Apparatus and Method" (see FIG. 9). An essential feature of 
the L-shaped design is that the radial thickness of the outer annular band 
portion must be sufficiently thin that it is magnetically saturated in 
order that the magnetic field intensities above the target can be made 
sufficiently great that the desired magnetic enhancement of the glow 
discharge takes place. The higher the magnetic permeability and the 
saturation magnetization of the material, the thinner the annular band 
portion must be. 
Magnetic sputter targets having an L-shaped profile contain much less 
material than nonmagnetic sputter targets of a generally inverted conical 
configuration. Moreover, the magnetic fields above the L-shaped magnetic 
targets lead to target erosion which is concentrated in the corner region. 
In relative terms, the inventory of magnetic target material usefully 
available for sputtering is therefore very limited. 
It is also known that a magnetic material heated to or above its Curie 
temperature loses its ferromagnetism while so heated. Another approach to 
avoiding excessive reduction in magnetic field intensities above the 
sputter target, therefore, is to heat the target and maintain it at or 
above its Curie temperature. A disadvantage of this approach is that it 
requires means for monitoring the temperature of the target, coupled with 
a feedback system for achieving and maintaining the required Curie 
temperature. Also, the Curie temperature of some magnetic materials is so 
high as to be detrimental to the adjacent substrate being coated and/or to 
the vacuum seals for the system and/or to cause damage to the sputter 
coating source or target as a result of warping or excessive thermal 
expansion. 
Most present-day magnetron sputter coating sources employ permanent magnets 
to provide the magnetic field required for glow discharge enhancement. As 
the sputter target erodes, the magnetic field intensities above the 
sputter target generally become stronger, leading to a lower electrical 
impedance of the glow discharge. This causes the sustainable voltage 
across the glow discharge to fall, bringing with it a decrease in 
sputtering yield. Maintaining a fixed sputtering rate, and hence a fixed 
coating rate, at a desired sputter gas pressure requires both higher 
current and a higher power. The glow discharge power supply must therefore 
be capable of providing extended ranges of voltage, current, and power, 
which adversely affects both power supply and power consumption costs. 
Additional factors affect the electrical impedance of glow discharges. 
Sputter gas pressure is one. Others include thermal effects (expansion, 
contraction, and Curie-temperature-related) in sputter targets and 
magnetic circuits. The permanent magnet means used in most present-day 
magnetron sputter coating sources do not provide compensation of glow 
discharge impedance changes arising from such factors. 
It is a well-known characteristic of glow discharges that the conditions 
for ignition (discharge initiation) and steady state operation are 
different. In some cases it is desirable to operate at a sputter gas 
pressure so low that ignition cannot occur with the magnetic fields in the 
sputter source (as provided by the usual permanent magnets) and the 
open-circuit voltage of the glow discharge power supply. One technique 
that can be used is to raise the sputter gas pressure sufficiently to 
allow ignition to occur, and then to reduce the sputter gas pressure to 
the desired operating level. Disadvantages of this approach include the 
relatively long time constants associated with the required pressure 
changes, plus the costs and complexity associated with controlling 
sufficiently quickly (that is, in times short in comparison with a coating 
cycle) the sputter gas pressure, which is normally controlled by flow rate 
and pumping speed. 
An ever-present problem in magnetron sputter coating sources is sputter 
target cooling. In normal operation, much of the glow discharge power is 
dissipated in the target. In the source described in above-mentioned U.S. 
Pat. No. 4,100,055, a cooling jacket surrounds the outer circumference of 
the target. Under conditions of normal operation, the target expands into 
tight contact with the cooling jacket, whereupon heat flows from the 
sputter target into the cooling jacket. This arrangement works well for 
target materials with adequate thermal conductivities, such as various 
aluminum alloys and mixtures. For target materials having relatively low 
thermal conductivities, as do many of the magnetic materials, cooling by 
this method may be insufficient. 
Another problem in magnetron sputter coating sources is that of predicting 
or determining the end of useful life. If an indirectly cooled sputter 
target is sputtered "through", sputtering of the target support member is 
likely to unacceptably contaminate the substrate being coated. If a 
directly cooled sputter target (that is, one in which the non-sputtered 
side is in contact with cooling water) is sputtered through, the entire 
associated vacuum chamber goes "up to water" (a situation to be 
assiduously avoided). 
One method of dealing with the end-of-useful-life problem is to determine 
empirically how long (for example, how many kilowatt-hours of operation) a 
sputter target of a particular configuration and material is good for, to 
maintain an accurate log of accumulated kilowatt-hours, and then to simply 
replace targets in accordance with a rigid schedule. While this approach 
may be entirely appropriate for routine production using a mature process, 
alternative approaches may be more desirable in the early stages of 
process development. In particular, independent means of assessing the 
erosion, or life, status of a sputter target during process development 
would be highly desirable. In addition, such a means would provide a 
useful diagnostic tool even for routine production. 
Yet another problem in the use of most magnetron sputter coating sources is 
that the distribution pattern of sputtered material arriving at the 
substrate being coated changes as the sputter target erodes during normal 
operation. With target erosion, the glow discharge moves into a region of 
higher magnetic field intensities. This causes the discharge to become 
increasingly concentrated, thereby producing an increasingly narrow groove 
as the erosion proceeds. This leads to changes in the distribution pattern 
of sputtered material (a "beaming" effect), and to a reduced inventory of 
usable sputter target material, with attendant reduced target life. 
Accordingly, it is an object of the invention to provide a magnetron 
sputter coating source which can utilize efficiently a large inventory of 
magnetic sputter target material. 
It is a further object of the invention to provide a magnetron sputter 
coating source which can utilize efficiently a large inventory of sputter 
target material, independent of magnetic permeability and saturation 
magnetization of the target material. 
It is also an object of the invention to provide a magnetron sputter 
coating source in which the sputter target configuration can be 
independent of magnetic permeability and saturation magnetization of the 
target material. 
It is another object of the invention to provide a magnetron sputter 
coating source in which a magnetic sputter target may be usefully operated 
at a temperature below the Curie temperature of the magnetic target 
material. 
It is a further object of the invention to provide a magnetron sputter 
coating source in which a means is provided for controlling the electrical 
impedance of the glow discharge in the face of changes which may occur due 
to sputter target erosion. 
It is yet another object of the invention to provide a magnetron sputter 
coating source in which a means is provided for controlling the electrical 
impedance of the glow discharge in the face of sputter target temperature 
changes. 
It is a still further object of the invention to provide a magnetron 
sputter coating source in which a means is provided for controlling the 
electrical impedance of the glow discharge in the face of magnetic circuit 
changes. 
It is another object of the invention to provide a magnetron sputter 
coating source in which a means is provided for controlling the electrical 
impedance of the glow discharge in the face of sputter gas pressure 
changes. 
It is an additional object of the invention to provide a magnetron sputter 
coating source in which a means is provided for effecting glow discharge 
ignition at a desired steady-state sputter gas operating pressure. 
Another object of the invention is to provide a magnetron sputter coating 
source in which an improved sputter target cooling means is provided. 
An additional object of the invention is to provide a magnetron sputter 
coating source in which an independent means of assessing sputter target 
erosion is provided. 
A further object of the invention is to provide a magnetron sputter coating 
source being a means for controlling the distribution pattern of sputtered 
material arriving at the substrate being coated, with such control being 
provided throughout the useful life of the sputter target. 
A still further object of the invention is to provide a magnetron sputter 
coating source in which a means is provided for increasing the useful life 
the sputter target. 
Additional objects and features will become apparent from the ensuing 
description of the invention. 
SUMMARY OF THE INVENTION 
The magnetron sputter coating source of the present invention differs from 
most prior art sources in that the magnetic field is provided by current 
flowing through an electromagnet coil rather than by a permanent magnet. 
In consequence, the magnetic field in the neighborhood of the sputter 
target may be conveniently and rapidly varied over a wide range of values, 
including zero. In the embodiments described, the electromagnet coil 
surrounds an inner cylinder. A base plate connects the inner cylinder with 
an outer cylinder to form a magnetic yoke. Inner and outer polepieces 
extend radially toward each other from the inner and outer cylinders. A 
radial gap between the polepieces is provided, and the sputter target is 
positioned atop this gap. The yoke and the polepieces are made of 
ferromagnetic materials having high magnetic permeabilities and high 
saturation magnetizations, such as soft iron or a magnetic stainless 
steel. The base plate and cylinders have sufficiently large 
cross-sectional areas transverse to the direction of the internal magnetic 
flux lines that a very low reluctance (low magnetic resistance) path to 
the polepieces is provided at the maximum electromagnet coil current (to 
produce maximum magnetomotive force) required during operation. 
When a sputter target of magnetic material is positioned atop the polepiece 
gap, it acts as a magnetic shunt at sufficiently low coil currents, 
whereby the magnetic field intensities adjacent the target are negligibly 
small. Upon increasing the coil current sufficiently, the onset of 
magnetic saturation of a portion of the target will occur. For a 
ring-shaped magnetic target of uniform thickness, this initial saturation 
will take place at a radius slightly greater than that of the inner 
polepiece, and fringing magnetic field lines will be established above and 
below the target near this radius. As the coil current is increased 
further, the magnetically saturated region will increase in radial extent, 
forming a high reluctance magnetic gap across which fringing magnetic 
field lines of increased intensity will be established. Unsaturated 
portions of the target will extend axially above the polepieces, and also 
radially inward and outward of the above-mentioned magnetic gap, thereby 
forming axial and radial extensions of the polepieces. At a particular 
required value of coil current, the configuration and intensities of 
magnetic fields above the target will permit the desired enhancement of 
the glow discharge to be achieved. This required value will increase with 
the magnetic permeability and the saturation magnetization of the target 
material, and also with target thickness. 
In the disclosed embodiments of the invention, magnetic field intensities 
large enough to permit the desired enhancement of the glow discharge are 
achieved with rewardingly small amounts of electromagnet coil power being 
required. For example, less than 50 watts of electromagnet coil power are 
needed to operate a magnetron sputter coating source in which the glow 
discharge power is in the 1 to 10 kilowatt range. This is true even for 
relatively thick magnetic sputter targets containing a desirably large 
inventory of usable material. 
When a nonmagnetic sputter target is used, the fringing magnetic fields 
above and below the target will be determined by the polepieces 
configurations and the electromagnet coil current. In general, a smaller 
coil current will be required with a nonmagnetic target than with a 
magnetic one. 
A polepiece configuration and spacing which is best for a sputter target 
material of high magnetic permeability and high saturation magnetization 
may work well for nonmagnetic targets. But better performance in terms of 
sputter target erosion patterns and material utilization may be obtained 
with a somewhat different polepiece configuration and separation. One 
feature of the invention is to provide readily replaceable and 
interchangeable polepieces so that a magnetron sputter coating source of a 
particular basic design can be used in optimum or near-optimum fashion 
with sputter targets having a wide range of magnetic characteristics. 
Another consequence of having readily replaceable and interchangeable 
polepieces is that the radial position of the sputter target erosion 
pattern may be shifted over a significant range in a particular magnetron 
sputter coating source, which may be important to the achievement of a 
desired distribution and uniform pattern in coating thickness on a 
substrate. 
Many features and characteristics of glow discharges depend upon magnetic 
field configurations and intensities above the sputter surface of the 
target, including discharge impedance, sputter gas pressure ranges for 
operation and for ignition, the configuration and position of the glow 
discharge, and the position and shape of the erosion pattern. An 
electromagnet coil means for providing the magnetic fields adjacent the 
sputter target allows these fields to be controlled and changed at will. 
Such control is accomplished with particular ease because of the 
relatively low electromagnet coil powers required in the disclosed 
embodiments of the present invention. 
Glow discharge impedance control is of particular importance because it can 
allow, for example, operation at a constant discharge voltage over a wide 
range of discharge currents. With sputter target erosion during normal 
operation, the glow discharge generally moves into a region of higher 
magnetic field intensities, which lowers the discharge impedance and 
voltage for a fixed sputter gas pressure. The lower discharge voltage 
leads to a reduced sputter yield from the target. To maintain a fixed 
coating deposition rate, it is necessary to increase both the current and 
the power in the discharge. Reducing the electromagnet coil current allows 
the magnetic field intensities to be reduced, bringing a return to the 
original discharge impedance and voltage. Electrical control of the 
magnetic field can, for example, maintain discharge voltage and current 
constant over the life of the sputter target. This has important 
implications to the design and construction of the glow discharge power 
supplies because the power supplies no longer have to provide a wide range 
of output voltage. 
When a sputter target erodes and the glow discharge moves into a region of 
higher magnetic field intensities, the discharge tends to become 
increasingly concentrated, thereby producing a relatively narrow groove as 
erosion proceeds. This leads changes in the distribution pattern of 
sputtered material, and to a reduced inventory of usable sputter target 
material (therefore reduced life). This effect is also alleviated by 
reducing magnetic field intensities through electromagnet coil current 
control. 
The radial position and the widths of the sputter target erosion pattern, 
and hence the distribution pattern of sputtered material, are influenced 
by the magnetic field intensities above the sputter surface. Electrical 
control of these magnetic field intensities therefore allows a measure of 
control to be exercised over this distribution pattern. 
It is known that the magnetic fields above the sputter target determine the 
ranges of sputter gas pressure both for ignition and for operation. In 
general for a given magnetic field distribution, a glow discharge will 
operate stably at pressures somewhat below the lowest pressure at which 
the discharge can be initiated. In some applications, operation at 
relatively low sputter gas pressures may be desirable because of reduced 
gas scattering of sputtered material en route from target to substrate. 
One method of obtaining ignition in such cases is to temporarily increase 
the sputter gas pressure, and then reduce it after the discharge has been 
initiated. With electrical control of magnetic fields available, a simpler 
and more convenient method of achieving ignition is to increase the 
electromagnet coil current momentarily while maintaining sputter gas 
pressure at the desired operating level. 
In some applications it may be desired to convert, either temporarily or 
for an extended period, an existing magnetron sputter coating source to a 
nonmagnetic diode sputtering apparatus or a sputter-etch cleaning station. 
Such a conversion is readily accomplished with the disclosed embodiment of 
the present invention simply by reducing the electromagnet coil current to 
zero (after reversal to achieve demagnetization, if necessary). 
Another feature of the present invention is the inclusion and use of a 
magnetic field sensor in the neighborhood of the sputter target. In the 
disclosed embodiments of the invention, the magnetic field sensor is a 
Hall probe located adjacent the water-cooled side of the sputter target 
near the radial position of maximum erosion. With magnetic targets, the 
magnetic field sensed by the Hall probe changes rapidly with target 
erosion. The end of useful life for sputter targets can be established 
empirically in terms of, for example, kilowatt-hours. An independent check 
on the status of magnetic sputter target erosion, and hence of the 
corresponding approach to the end of useful life, can usefully and 
conveniently be made using the above-mentioned magnetic field sensor. In 
short, the Hall probe magnetic field sensor is a valuable diagnostic tool. 
When a nonmagnetic sputter target is employed, it is useful, as discussed 
previously, to adjust the magnetic fields electrically to allow, for 
example, constant voltage operation of the discharge. The Hall probe can 
be beneficially used to monitor the local magnetic field, which can be 
independently correlated with sputter target erosion and the approach to 
the end of useful life. 
Disclosed in one of the embodiments of the invention is a novel sputter 
target cooling means. The bottom side of the target is in contact with a 
water chamber. A septum divides the chamber into inlet and outlet 
portions. In flowing from inlet to outlet, the water is constrained to 
flow through a narrow gap between the top of the septum and the bottom of 
the target. The septum is located directly under the region of maximum 
target erosion. The sputter target may thus be cooled efficiently and 
uniformly adjacent the region of maximum power dissipation. 
In the case of a magnetic target in particular, the Hall probe can provide 
valuable independent information regarding the approach to the end of 
useful life, thereby helping to avoid a catastrophic leak from the water 
chamber through the sputter target.

DETAILED DESCRIPTION 
The sputter coating source of FIG. 1 includes a central anode assembly 10, 
an outer anode 11, and a sputter target 13, which serves also as a 
cathode. Apart from sputter target 13, the magnetic circuit comprises an 
electromagnet coil 20 with electrical feedthroughs and connectors 21, a 
hollow central cylinder 22, a base plate 23, a hollow outer cylinder 24, 
an outer polepiece 25 (shown integral with cylinder 24), and an inner 
polepiece 27. All parts 22-27 are of high permeability, high saturation 
ferromagnetic materials, such as soft iron and magnetic stainless steel, 
and are relatively massive to provide a low resistance magnetic path, with 
the largest magnetic resistance being provided by sputter target 13 across 
the gap between polepieces 25 and 27. 
Base plate 23 is attached by a plurality of screws (not shown) to cylinders 
22 and 24 to form a magnetic yoke. Polepiece 27 is attached to cylinder 22 
by means of a plurality of screws 30 (2 shown), and a vacuum seal is 
provided between parts 27 and 22 by O-rings 31 and 32. An interior flange 
34 is welded or brazed to polepiece 27 for supporting central anode 
assembly 10. An exterior flange 36 is welded or brazed to cylinder 24 to 
provide insulative connection with outer anode 11, in a manner similar to 
that shown for the embodiment of FIG. 2. Sputter target 13 is affixed to 
polepiece 25 by an outer clamp 38, and to polepiece 27 by an inner clamp 
39. A plurality of screws 40 (4 shown) attach clamps 38 and 39 to 
polepieces 25 and 27, and O-rings 41 and 42 provide the vacuum seal 
between sputter target 13 and polepieces 25 and 27. 
Water cooling of sputter target 13 is accomplished with the aid of a 
manifold 45. Manifold 45 is held in firm contact with polepieces 25 and 27 
by base plate 23, and a vacuum seal between manifold 45 and polepieces 25 
and 27 is provided with the aid of O-rings 46 and 47. A water inlet 
conduit 49 passes through a clearance bore 50 through cylinder 24 and is 
sealed into a first horizontal bore 51 in manifold 45. A first vertical 
bore 52, a second horizontal bore 53, and a second vertical bore 54 
complete the water flow path through manifold 45. Bore plugs 55 and 56 are 
sealed as shown to confine the water flow path. A cylindrical septum 60 is 
attached to the top surface of manifold 45 to form an inlet annulus 61 and 
an outlet annulus 62. In a manner similar to that shown for the inlet 
portion, one or more outlet conduits (not shown) are connected via a 
series of horizontal and vertical bores to outlet annulus 62. A spacing 64 
between the top edge of septum 60 and the bottom surface of sputter target 
13 is made uniformly small to ensure an adequate but high impedance flow 
of water under the bottom surface of sputter target 13 to provide uniform 
cooling around the circumference thereof. 
A Hall probe 67 for measuring magnetic field strengths is located below 
sputter target 13 and between inlet and outlet annuluses 61 and 62. Four 
electrical leads 68 (two shown) are connected through a conduit 69 to Hall 
probe 67. Conduit 69 passes through horizontal clearance bore 70 through 
cylinder 24, and is sealed into a first horizontal bore 71 in manifold 45. 
A first vertical bore 72, a second horizontal bore 73, and a second 
vertical bore 74 provide a path for electrical leads 68 from Hall probe 67 
through conduit 69. Bore plugs 75 and 76 serve to seal the passageway. A 
length of capped tubing 80 surrounds Hall probe 67 and is brazed or welded 
into second vertical bore 74. As illustrated in FIG. 1, the radial 
position of Hall probe 67 is essentially the same as that of septum 60. 
The presence of surrounding capped tubing 80 therefore introduces an 
interruption of cylindrical septum 60 between inlet annulus 61 and outlet 
annulus 62. A spacing 84 between the top surface of capped tubing 80 and 
the bottom surface of sputter target 13 is chosen to provide substantially 
the same high impedance to water flow as that provided by spacing 64 for 
septum 60. 
Central anode assembly 10 is insulatively mounted on interior flange 34. An 
insulating ring 86 is secured to flange 34 by a plurality of screws 87 
(one shown), and a vacuum seal between ring 86 and flange 34 is provided 
by an O-ring 88. A base member 90 is fastened to insulating ring 86 with a 
plurality of screws 91 (one shown), with a vacuum seal being provided with 
the aid of an O-ring 92. Base member 90 includes a hollow cylindrical 
section 94 to which is attached a top cap 95, whereby water cooling 
chamber 96 is formed. An inlet water line 97 and an outlet water line 98 
connect to chamber 96, whereby water cooling of central anode assembly 10 
may be accomplished. A central disk 100 is attached to top cap 95 by means 
of a central screw 101. Attached to central disk 100 is a right angle 
member 103 consisting of a cylindrical portion 104 and a flat ring portion 
105. 
A support means for outer anode 11 is not shown in FIG. 1. Outer anode 11 
may, however, be supported in the manner shown below for the anode in the 
embodiment of FIG. 2. 
The magnetron sputter coating source of FIG. 2 includes an anode 111 and a 
sputter target (cathode) 113. Apart from target 113, the magnetic circuit 
comprises an electromagnet coil 120, with electrical fittings and 
connections 121, a central cylinder 122, a base plate 123, a hollow outer 
cylinder 124, an outer polepiece 125, a top plate 127, and an integral 
inner polepiece 128. Taken together, parts 122, 123, 124, and 127 form a 
magnetic yoke between polepieces 125 and 128. Parts 122-128 are made of 
high permeability, high saturation ferromagnetic materials of 
comparatively large cross-section to provide a low impedance magnetic path 
through polepieces 125 and 128. A nonmagnetic ring 129 is brazed or welded 
to polepieces 125 and 128, forming a vacuum tight joint thereto. A screw 
130 secures top plate 127 to central cylinder 122, and an O-ring 131 
provides the vacuum seal between plate 127 and cylinder 122. Similarly at 
the bottom a screw 133 secures base plate 123 to cylinder 122, and an 
O-ring 134 provides the vacuum joint between base 123 and cylinder 122. A 
plurality of screws (not shown) secures base plate 123 to outer cylinder 
124, and an O-ring 135 provides a vacuum seal between plate 123 and 
cylinder 124. An exterior flange 136 is welded or brazed to the outside of 
outer cylinder 124 to allow insulative attachment to a vacuum chamber or 
to a processing station, and also to anode 111. 
A plurality of screws 138 (two shown) secure polepiece 125 to outer 
cylinder 124, and an O-ring 139 provides the vacuum seal between polepiece 
125 and cylinder 124. Sputter target 113 is secured to polepieces 125 and 
128 by an outer clamp 141 and an inner clamp 142 which are in turn secured 
by a plurality of screws 143 (two shown for clamp 142, none shown for 
clamp 141). 
Coil 120 partially surrounds central cylinder 122. A coil jacket 145 
partially surrounds coil 120. Jacket 145 includes a cylindrical portion 
146 and a flat ring portion 147. An O-ring 148 provides a water-tight 
joint between base 123 and cylindrical portion 146, and an O-ring 149 
provides a water-tight jacket between inner cylinder 122 and flat ring 
portion 147. A step 151 in inner cylinder 122 engages the top surface of 
flat ring portion 147. A water cooling chamber 153 is formed, bounded by 
the inner surface of cylinder 124, top surface of base 123, outer surface 
of coil jacket 145, outer portion of step 151, portions of polepieces 125 
and 128, and the bottom surface of nonmagnetic ring 129. Water is 
introduced into chamber 153 through a plurality of squirt tubes 154 (two 
shown), which are introduced through penetrations in base plate 123. These 
squirt tubes direct a plurality of water jets onto the bottom surface of 
nonmagnetic ring 129 to provide cooling of sputter target 113. Outlet for 
return water flow is provided by means not shown. 
The positioning of Hall probe 67 adjacent sputter cathode 13 has been 
described previously in connection with FIG. 1. A Hall probe 156 inside a 
capped tube 157 is shown schematically inside chamber 153 positioned 
closely adjacent nonmagnetic ring 129. Although not explicitly shown in 
FIG. 2, a squirt tube 154, for example, could be readily modified to 
provide a straightforward means of introducing and positioning Hall probe 
156. 
Anode 111 is formed of an outer disk portion 160, a cylindrical portion 
161, and an inner disk portion 162. A plurality of screws 164 (two shown) 
secure anode 111 to a mounting plate 165. An insulating ring 167 is 
secured to mounting plate 165 by means of a plurality of screws 168 (one 
shown), and an O-ring 169 provides a vacuum seal between insulating plate 
167 and mounting plate 165. Exterior flange 136 is engaged by means not 
shown and held in contact with insulating ring 167, and an O-ring 171 
provides the vacuum seal between flange 136 and ring 167. Mounting plate 
165 is engaged by means not shown with a flange 180. Flange 180 may, for 
example, connect to a vacuum system or to a processing station. The vacuum 
joint between mounting plate 165 and flange 180 is provided by an O-ring 
181. 
FIG. 3 shows a fragmentary section of sputter target 113 of FIG. 2. In FIG. 
3, sputter target 113 has an inner radius of 1.75 inches, an outer radius 
of 3.56 inches, and a thickness or vertical height of 0.375 inches. 
In FIG. 3, representative magnetic field lines 201 are shown qualitatively 
above the target. Among other things, the shape of magnetic field lines 
201 depends strongly on the level of magnetic saturation of the magnetic 
material of target 113. Sputter target 113 has an uneroded surface profile 
203 when new. After operating a sputter target 113 made of 410 stainless 
steel for 52.6 kilowatt-hours at constant current to electromagnet coil 
120, profile 204 was obtained. After operating a sputter target 113 made 
of Permalloy for 57.5 kilowatt-hours, with current to electromagnet coil 
120 adjusted to maintain constant magnetic field as measured by Hall probe 
156, profile 205 was obtained. An end-of-useful-life profile 207 is 
estimated for the above Permalloy target. The useful life for the target 
is estimated to be in excess of 100 kilowatt-hours. 
FIG. 4 shows a curve 210 of Hall probe 156 output voltage as a function of 
operating life (measured in kilowatt-hours) of a Permalloy sputter target 
113. This is the same target that gave rise to profile 205 in FIG. 3. As 
previously noted, profile 205 was obtained after 57.5 kilowatt-hours of 
operation, with current to coil 120 adjusted to maintain constant magnetic 
field as measured by Hall probe 156. 
Curve 210 was generated by periodically returning the coil 120 current to a 
fixed value (4.0 amps, with sputter source operation interrupted) and 
measuring Hall probe 156 output voltage. This voltage is proportional to 
the magnetic field at the Hall probe location. It may be seen from curve 
210 that this magnetic field rose by over 50% during the first 40 hours of 
operation. 
To operate the magnetron sputter coating source of FIG. 1, it is first 
installed, for example, on a mating flange of an evacuable chamber. 
Central anode assembly 10 and outer anode 11 may be tied together 
electrically and connected to the positive voltage terminal of a glow 
discharge power supply. The positive terminal of the supply may optionally 
be connected to ground. Alternatively, central anode assembly 10 may be 
separately connected to permit biasing with respect to outer anode 11. The 
magnetic circuit includes a magnetic yoke (consisting of base plate 23 and 
cylinders 22 and 24) associated polepieces 25 and 27, plus sputter target 
13. These parts are electrically joined together, and are electrically 
insulated from anodes 10 and 11. Because of its position relative to 
anodes 10 and 11 and to polepieces 25 and 27, sputter target 13 serves as 
the cathode of the sputter source. During operation, the magnetic circuit 
and the cathode are connected to the negative terminal of the glow 
discharge power supply. Electromagnet coil 20 is energized through 
electrical connectors 21 by a variable-voltage magnet power supply. The 
magnetic field above the sputter surface of target 13 depends both upon 
the current in electromagnet coil 20 and on the magnetic permeability and 
saturation magnetization characteristics of the material of which sputter 
target 13 is made. 
The current required to sensitize Hall probe 67 is provided by a Hall probe 
control unit connected to electrical leads 68. The resulting Hall voltage 
is proportional to the magnetic field at the location of Hall probe 67, 
and is measured by the Hall probe control unit. Cooling water is supplied 
to water inlet conduit 49 for sputter target 13 and to inlet water line 97 
for central anode assembly 10. 
After evacuation, the chamber on which the magnetron sputter coating source 
has been installed is backfilled to a subatmospheric pressure of a sputter 
gas, which is usually argon. When sputter gas pressure and magnetic field 
intensities above sputter target 13 are within their appropriate ranges, 
operation of the magnetron sputter coating source can be initiated with 
the application of a required voltage from the glow discharge power 
supply, and coating of a substrate with material from sputter target 13 
can commence. 
Operation of the magnetron sputter coating source of FIG. 2 is essentially 
the same as for the source of FIG. 1. Unlike the source of FIG. 1, the 
source of FIG. 2 has no central anode. Anode 111 is connected to the 
positive terminal of the glow discharge power supply. The magnetic circuit 
comprises base plate 123, cylinders 122 and 124, top plate 127, which form 
a magnetic yoke, and polepieces 125 and 128, plus sputter target 113. 
Nonmagnetic ring 129 forms a vacuum seal to polepieces 125 and 128. The 
magnetic circuit parts are electrically joined together, and are insulated 
from anode 111. Because of its position relative to anode 111 and to 
polepieces 125 and 128, sputter target 113 serves as the cathode of the 
sputter source. During operation, the magnetic circuit and the cathode are 
connected to the negative voltage terminal of the glow discharge power 
supply. Electromagnet coil 120 is energized through electrical connectors 
121 by a variable-voltage magnet power supply. Magnetic field intensities 
above the sputter surface of sputter target 113 depend both on the current 
in electromagnet coil 120 and on the magnetic permeability and saturation 
magnetization characteristics of the material of which sputter target 113 
is made. 
The current required to sensitize Hall probe 156 is provided by a Hall 
probe control unit, and the Hall voltage generated by Hall probe 156 is 
measured by the Hall probe control unit. Water for cooling sputter target 
113 is injected into chamber 153 by a plurality of squirt tubes 154 
directed toward the bottom of nonmagnetic ring 129. 
After evacuation, the chamber on which the magnetron sputter coating source 
has been in stalled is backfilled to a subatmospheric pressure of a 
sputter gas, which is usually argon. When sputter gas pressure and 
magnetic field intensities above sputter target 113 are within their 
appropriate ranges, operation of the magnetron sputter coating source can 
be initiated with the application of a required voltage from the glow 
discharge power supply, and coating of a substrate with material from 
sputter target 113 can commence. 
As an example, a sputter target 113 shown in FIG. 3 (inner radius equals 
1.75 inches, outer radius equals 3.56 inches, vertical height equals 0.375 
inches), and made of Permalloy, requires a current in electromagnet coil 
120 of approximately 6 amperes (at less than 5 volts for an electromagnet 
power of less than 30 watts) to produce magnetic field intensities above 
the uneroded surface 203 of sputter target 113 sufficient to allow normal 
magnetic enhancement of the glow discharge. Representative magnetic field 
lines 201 above uneroded surface 203 are shown qualitatively in FIG. 3. 
The corresponding "magnetic tunnel" serves to confine the glow discharge. 
The resulting magnetically enhanced glow discharge operates at 600 volts 
and 1.7 amperes (for a glow discharge power of 1.0 kilowatts) at an argon 
sputter gas pressure of 4.times.10.sup.-3 Torr, resulting in a substrate 
coating rate of approximately 1400 Angstroms per minute at a sputter 
target-to-substrate distance of 2.5 inches. 
As operation of the magnetron sputter coating source continues, the sputter 
surface of target 113 is eroded away. In one experiment using a target 113 
made of 410 stainless steel and operated at a fixed current of 7 amperes 
to electromagnet coil 120, eroded surface profile 204 was obtained after 
52.6 kilowatt-hours of operation. As the erosion proceeded, the magnetic 
field intensities above the sputter surface increased, leading to a more 
tightly confined and lower voltage glow discharge. By the time profile 204 
was obtained, the magnetic field intensities immediately above profile 204 
had become large enough to render the glow discharge unstable. Because of 
this unstable operation, end of useful life at the coil current of 7 
amperes had been reached for this target. 
In a second experiment, a sputter target 113 made of Permalloy was operated 
with the current to electromagnet coil 120 being continually reduced to 
maintain a constant output Hall voltage from Hall probe 156. In this way, 
the magnetic field intensity at the position of Hall probe 156 was held 
constant as the sputter surface of target 113 was eroded away. 
Correspondingly, the magnetic field intensities above the sputter surface 
of target 113 changed comparatively little with target erosion, leading to 
a more nearly constant glow discharge impedance and to stable operation. 
Eroded surface profile 205 was obtained after 57.5 kilowatt-hours of 
operation. 
As erosion of sputter target 113 proceeded toward profile 205, operation 
was interrupted periodically and the Hall voltage from the Hall probe 156 
was measured with the current to electromagnet coil 120 returned to a 
reference value of 4 amperes. The results of these measurements are shown 
in curve 210 of FIG. 4. It may be seen from curve 210 that the magnetic 
field sensed by Hall probe 156 rose by over 50% during the first 40 
kilowatt-hours of operation. 
A comparison of profiles 204 and 205 reveals that operation at constant 
electromagnet coil current (profile 204) caused the erosion profile to be 
deeper and more sharply concentrated than operation at constant Hall 
voltage (profile 205). From this it is clear that the inventory of usable 
target material before end of useful life is reached is significantly 
greater under profile 205 operating conditions than under those for 
profile 204. 
Another comparison of profiles 204 and 205 shows that the radius of maximum 
erosion is smaller for profile 204 than for profile 205. This is 
presumably due to the increase during operation in magnetic field 
intensities above the sputter surface of target 113. Associated with a 
change in the radius of maximum erosion is a change in the distribution 
pattern of sputtered material arriving at the substrate. In addition, the 
difference in the radii of maximum erosion for profiles 204 and 205 shows 
that magnetic field intensity changes (brought about by changes in the 
current to electromagnet coil 120) can be utilized to provide a measure of 
control over the radius of maximum erosion, and hence corresponding 
control over the distribution pattern. 
An end-of-useful-life profile 207 has been estimated for sputter target 
113. It has been further estimated that more than 100 kilowatt-hours of 
operation are required to reach profile 207. The significance of this is 
that the inventory of usable magnetic material contained in sputter target 
113 is large enough to be of practical use in coating equipment for 
magnetic disk manufacture. The amount of usable magnetic material is, in 
fact, comparable with the amount of usable nonmagnetic material contained 
in the targets of many prior-art magnetron sputter coating sources. 
One of the keys to success of the present invention is the use of an 
electromagnet rather than a permanent magnet. In prior-art magnetron 
sputter coating sources using permanent magnets and nonmagnetic sputter 
targets, target erosion usually leads to operation in magnetic fields of 
progressively greater intensities, with resulting changes in discharge 
impedance. It has been feasible to accommodate these changes through power 
supply design. With magnetic sputter targets, as the above-described 
experiment leading to profile 204 shows, the magnetic field intensities 
adjacent the target change much more rapidly with target erosion. As 
stated earlier, by the time eroded profile 204 was reached after 52.6 
kilowatt-hours of operation, the glow discharge had become unstable. In 
effect, then, the end of useful life had been reached. Only by reducing 
the magnetomotive force, which in this case could be readily accomplished 
by reducing the current to electromagnet coil 120, could stable operation 
be achieved. 
It is evident to one skilled in the art of magnetron sputter coating source 
design that sputter targets 13 and 113 made of nonmagnetic materials could 
be used effectively and efficiently in the magnetron sputter coating 
sources shown in FIGS. 1 and 2. It is possible that optimum configurations 
of polepieces 25 and 27 of FIG. 1 and polepieces 125 and 128 and FIG. 2 
would be somewhat different for use with nonmagnetic materials than for 
use with strongly ferromagnetic materials. Inner polepieces 27 in FIG. 1 
is shown as separate from cylinder 22 to facilitate replacing it with one 
of a different configuration, should that become necessary or desirable. 
In FIG. 2, top plate 127 with integral polepiece 128 is shown as readily 
removable, as is outer polepiece 125. The magnetron sputter coating 
sources of FIGS. 1 and 2 are thus well suited for use with sputter targets 
13 and 113 having properties ranging from nonmagnetic to strongly 
ferromagnetic. 
It has been mentioned previously that sputter target erosion leads to 
increasing magnetic field intensities above the sputter target surface, 
which leads in turn to a lower electrical impedance of the glow discharge, 
which reduces the voltage that can be sustained across the discharge at a 
given power level. Alternatively, operation at constant voltage leads to 
increased current, higher power, and higher sputtering rate, which may be 
undesirable. To maintain a fixed sputtering rate at a desired sputter gas 
pressure, it is necessary to operate at both higher current and higher 
power levels. The glow discharge power supply must therefore be capable of 
providing extended ranges of voltage, current, and power, which adversely 
affects both power supply and power consumption costs. The use of an 
electromagnet rather than a permanent magnet in the magnetron sputter 
coating sources of the present inventon makes for straightforward 
electrical control of the magnetic field intensities above the sputter 
target, thereby making it feasible to operate at constant values of glow 
discharge voltage, current, and power, for example, throughout sputter 
target life. This is so for both magnetic and nonmagnetic targets. 
Significant savings in both glow discharge power supply and power 
consumption costs should therefore be achievable. 
The magnetic circuit designs employed in the disclosed embodiments of the 
present invention lead to very low reluctance magnetic paths and low 
magmetic losses. As a result, the electromagnet power required is low and 
control of the current to electromagnet coil 20 or 120 is relatively 
straightforward. It may well be that the cost savings achieved in glow 
discharge power supplies as a result of constant voltage operation will 
more than offset the cost of the magnet power supplies. 
As mentioned previously, it is sometimes desirable to operate a glow 
discharge at a sputter gas pressure below the minimum pressure at which 
the discharge will ignite spontaneously with the normal application of 
voltage from the glow discharge power supply. One approach to this problem 
is to raise the sputter gas pressure sufficiently to allow ignition to 
occur, and then reduce sputter gas pressure to the desired operating 
level. Disadvantages of this approach include costs, complexity, and 
relatively long time constants (a significant fraction of the sputter 
coating times), as discussed earlier. With electrical control readily 
available of the magnetic field intensities adjacent the sputter surface 
of the targets 13 and 113, glow discharge ignition can be facilitated with 
a brief increase in current to the electromagnet coils 20 and 120. 
In magnetron sputter coating sources generally, the cooling of sputter 
targets has posed one of the more challenging and pervasive problems. The 
approach to target cooling described in, for example, the aforementioned 
U.S. Pat. No. 4,100,055 employs a cooling jacket surrounding the outer 
circumference of the target. As discussed earlier, this approach to 
cooling sputter targets having relatively low thermal conductivities, as 
do many of the magnetic materials, may prove inadequate. In the embodiment 
shown in FIG. 2, sputter target 113 is held in contact with polepieces 125 
and 128 and with nonmagnetic ring 129 by clamps 141 and 142. As shown, a 
plurality of squirt tubes 154 directs jets of cooling water onto outer 
polepieces 125 and ring 129. The main impedance to heat transfer from 
sputter target 113 occurs at the interface between the bottom surface of 
sputter target 113 and the top surfaces of polepieces 125 and 128 and ring 
129. Cooling of sputter target 113 may thus be aptly termed "indirect". 
This indirect cooling configuration is adequate for most magnetic sputter 
targets 113 of the dimension shown in FIG. 3 up to glow discharge power 
levels of perhaps 1 to 2 kilowatts, but may become inadequate at higher 
powers. Target warping, cracking, and even local melting may occur as a 
result of inadequate cooling. 
The cooling means disclosed in FIG. 1 for sputter target 13 replaces the 
indirect cooling (as for sputter target 113) by a "direct" cooling in 
which the cooling water (or other coolant) is in direct physical contact 
with the bottom surface of sputter target 13, with no intervening thermal 
impedance imposed by the equivalent of nonmagnetic ring 129 of FIG. 2. A 
plurality of squirt tubes similar to squirt tubes 154 of FIG. 2 could be 
used to direct jets of cooling water onto the bottom surface of sputter 
target 13. Because cooling would be direct rather than indirect, operation 
at substantially increased glow discharge power levels would be feasible. 
The cooling means shown in FIG. 1 employs cylindrical septum 60 atop 
manifold 45 to divide the water cooling chamber into inlet annulus 61 and 
outlet annulus 62. Spacing 64 between the top of septum 60 and the bottom 
surface of sputter target 13 is chosen to force a radial flow of water 
which is essentially uniform along the circumference of septum 60 from 
inlet annulus 61 to outlet annulus 62. In this way, the circumferential 
variations in cooling that could result from a set of separated squirt 
tubes is avoided. In addition, simplification of the water distribution 
system is achieved. By choosing spacing 64 and water flow rates 
appropriately, turbulent flow over the bottom surface of sputter target 13 
can be assured, thereby avoiding the formation of the stagnant fluid 
layers which inhibit heat transfer. 
The above-described direct cooling system emplying septum 60 with spacing 
64 thus provides a novel approach to the problem of sputter target cooling 
in magnetron sputter coating sources. 
Direct cooling of sputter target 13 places a particular premium on avoiding 
warping, cracking, or melting of sputter target 13 which, if it occurred, 
would let the vacuum system "up to water"; this is a catastrophe to be 
assiduously avoided. The uniform circumferential cooling provided with the 
aid of septum 60 and spacing 64 greatly alleviates the problems of leaks 
due to warping, cracking, or melting. As the end of useful life is 
approached, the danger of a leak developing in sputter target 13 
increases. One approach to determining when end of useful life is imminent 
is to simply keep track of the amount of sputter target life already used, 
measured, for example, in kilowatt-hours, and to stop operation when an 
empirically-established end-of-useful-life point has been reached. The 
absence or loss of such data makes it desirable to have alternative 
methods of determining when the end of useful life is near at hand. A 
second approach is to correlate the erosion status of sputter target 13 
with the current to electromagnet coil 20 required to maintain a constant 
glow discharge operating voltage at a fixed sputter gas pressure and a 
fixed discharge power level. This coil current will decrease as target 
erosion proceeds, and the magnitude of the required coil currents will be 
higher for magnetic targets than for nonmagnetic ones. A third approach is 
to monitor the change in Hall voltage from Hall probe 67, at a fixed 
reference value of current to electromagnet coil 20, for example (as in 
FIG. 4), and to correlate this Hall voltage with the erosion of sputter 
target 13. Although this third approach is not usable with nonmagnetic 
sputter targets, (the Hall voltage should be independent of nonmagnetic 
sputter target erosion), it provides a particularly sensitive measure of 
sputter target erosion when used with strongly ferromagnetic sputter 
targets. 
It will be seen from the foregoing that the present invention provides a 
novel magnetron sputter coating source capable of dispensing relatively 
large inventories of sputter target materials having magnetic properties 
ranging from nonmagnetic to highly ferromagnetic, with additional useful 
features relating to glow discharge power supplies, discharge ignition, 
target cooling, and target life monitoring. Although many modifications of 
the disclosed embodiments will occur to those skilled in the art, it is 
understood that this invention is to be limited only by the scope of the 
appended claims.