Ion beam sputtering system

Abstract: An ion beam sputtering system having a chamber and a target, a substrate, and a movable flux regulator located between the target and the substrate in the chamber. The position of the movable flux regulator relative to the deposition substrate affects the thickness uniformity of thin films deposited on the substrate in the ion beam sputtering system.

Description: This invention relates generally to the fabrication of thin films by ion beam sputter deposition. It is well-known in the prior art to utilize RF or DC magnetron sputter-deposition apparatus for fabrication of thin film devices such as magnetic recording sensors and storage media. Such sputter devices are characterized by crossed electric and magnetic fields in an evacuated chamber into which an inert, ionizable gas, such as argon, is introduced. The gas is ionized by electrons accelerated by the electric field, which forms a plasma in proximity to a target structure. The crossed electric and magnetic fields confine the electrons in a zone between the target and substrate structures. The gas ions strike the target structure, causing ejection of atoms that are incident on a workpiece, typically a substrate on which it is desired to deposit one or more layers of selected target materials. In the prior art conventional sputtering devices relatively high operating pressures are utilized in order to obtain films having low internal stress which results in non-directional sputtering flux at the substrate. However, this non-directional flux introduces manufacturing process difficulties as device dimensions become increasingly smaller. It is known in the prior art to utilize ion beam sputter deposition in certain applications to overcome some of the difficulties encountered with conventional RF/DC sputter techniques. Several aspects of ion beam sputter deposition differ from conventional sputter processes and provide significant advantages. For example, (1) the use of low background pressure results in less scattering of sputtered particles during the transit from the target to the substrate; (2) control of the ion beam directionality provides both a variable angle of incidence of the beam at the target and a controllable angle of deposition at the substrate; (3) a nearly monoenergetic beam having a narrow energy distribution provides control of the sputter yield and deposition process as a function of ion energy and enables accurate beam focusing and scanning; and (4) the ion beam is independent of target and substrate processes which allows changes in target and substrate materials and geometry while maintaining constant beam characteristics and allowing independent control of the beam energy and current density. Apparatus and methods for producing a thin film deposit on a substrate utilizing ion beam sputtering are described, for example, in U.S. Pat. No. 4,923,585 ('585) to Krauss et al. and in U.S. Pat. No. 5,492,605 to Pinarbasi ('605). Krauss et al discloses the use of a computer controlled, single ion beam with a quartz crystal monitor to produce deposited films of arbitrary composition as well as layered structures of arbitrary thickness from multiple targets of elemental components of the desired films and layered structures. Pinarbasi discloses matching the ion beam gas atomic mass to the target material atomic mass to provide thin films having densities and physical properties very close to their bulk property values. Both the mass of the ion beam sputtering gas and the energy of the ion beam is controlled as a function of the target material to provide single-layered and multilayered structures wherein selected properties of each layer are optimized to provide specific function for each layer in the resulting structure. While the '585 and '605 patents disclose methods for depositing multilayer films and controlling the physical properties, the problems of controlling and improving the thickness uniformity across the wafer of each individual layer deposited are not addressed. Document US-A-4793908 discloses the use of a mask to improve the uniformity of the thin film thickness; by tailoring the mask shape, it is possible to provide compensation for radial non-uniformities across the substrate. The article Motohiro T et al: "Angular-resolved ion-beam sputtering apparatus for large-area deposition" Review of Scientific Instruments, vol.60, no.8, 1 August 1989, pages 2657-2665, ISSN: 0034-6748 describes a q-setting slit for the ion-beam sputter deposition geometry. Ion beam sputter deposition systems have been utilized to deposit individual layers of anisotropic magnetoresistive (AMR) sensors and giant magnetoresistive (GMR) sensors for use in magnetic recording devices. In the GMR sensors, for example, the resistance of the magnetoresistive (MR) sensing layer varies as a function of the spin-dependent transmission of the conduction electrons between the ferromagnetic layers separated by a non- magnetic layer (spacer) and the accompanying spin-dependent scattering which takes place at the interface of the ferromagnetic and non-magnetic layers and within the ferromagnetic layers. GMR sensors using only two layers of ferromagnetic material (e.g., NiFe or Co or NiFe/Co) separated by a layer of GMR promoting non-magnetic metallic material (e.g., copper) are generally referred to as spin valve (SV) sensors. Magnetoresistive (MR) sensors (AMR or GMR) are very small devices that are generally fabricated by sputtering depositions on large wafer substrates which are generally larger than 5 inches in diameter to form thousands of sensors that will be subsequently separated (diced) to form individual magnetic read transducers for use in magnetic storage devices. One of the critical issues in the fabrication process of MR sensors is the thickness uniformity of each and every deposited layer over the entire utilized area of the wafer in order to control the uniformity of operating characteristics (for example, resistance and magnetoresistance) of the entire batch of the MR sensors fabricated on the wafer substrate. In an experiment by the present applicant, an ion beam sputtering system (Fig. 1) having a non-movable flux regulator was developed and used to build SV sensors 200 (Fig. 2) on a 5 inch diameter wafer substrate (Fig. 3) in order to measure the uniformity of physical properties of the various sputtered layers (therefore, uniform thickness). Referring to Fig 1 , there is shown a simplified diagram illustrating the ion beam sputter deposition system 120 developed and used by the Applicant. The ion beam sputter deposition system 120 includes a vacuum chamber 122 in which an ion beam source 121 is mounted. The ion beam system 120 further comprises a target 123 and a workpiece (also referred to as a deposition substrate or wafer substrate) 131 . An ion beam 133 provided by the ion source 121 is directed at the target 123 where the impacting ions cause sputtering of the target material. System 120 further included selectable multiple targets 123 on a rotary target support 125 . The sputtered atoms 126 emitted from the target material is directed onto a deposition substrate 131 on which is formed a layer of the target material. A thickness monitor 137 positioned closely adjacent to the substrate 131 provides real-time, in-situ monitoring of the thickness of the growing film during deposition. A non-movable flux regulator 150 fixed in front of the deposition substrate 131 partially blocks the sputtered atom flux and is used in conjunction with rotation of the deposition substrate 131 to improve thickness uniformity of the deposited layer. Applicant's non-movable flux regulator refers to a flux regulator whose position was fixed prior to the ion beam sputtering deposition of one or more deposited layers and never changed during the deposition of said one or more deposited layers. The substrate or other workpiece 131 is mounted on a movable pedestal or support member 141 which is retrieved into a loading port 139 via a gate valve 138 for changing the workpiece 131 . A magnetic field may also be applied at the workpiece 131 if required for the particular structure being deposited. The pedestal 141 may also be rotated, using a rotary/linear motor, during deposition to rotate the deposition substrate 131 . During operation of the ion beam sputter deposition system, the vacuum chamber 122 is maintained at suitable low pressure by a vacuum pump (not shown) via port 135 . Fig. 2 shows the SV sensor 200 manufactured using Applicant's ion beam sputtering system 120 . SV sensor 200 comprises end regions 204 and 206 separated by a central region 202 . A free layer (free MR layer, free ferromagnetic layer) 210 is separated from a pinned layer (pinned MR layer, pinned ferromagnetic layer) 220 (which may include a very thin Co interface layer 218 ) by a non-magnetic, electrically-conducting spacer layer 215 . Alternatively, pinned layer 220 may be made of multi layers of ferromagnetic material (e.g., cobalt, Nife) separated from each other by a metallic non-magnetic conductor (e.g., ruthenium). Such a multi-layer pinned layer is generally referred to as anti-parallel (AP) pinned layer. The magnetization of the pinned layer 220 is generally, although not necessarily, is fixed through exchange coupling with an antiferromagnetic (AFM) layer 225. The AFM layer 225, is generally made of NiMn, FeMn or NiO. The magnetization of the free layer, however, is free to rotate in response to an external field. Free layer 210 , spacer layer 215 , pinned layer 220 and the AFM layer 225 (if used) are all formed in the central region 202 over the substrate 228 . Hard bias layers 230 and 235 formed in the end regions 204 and 206 , respectively, provide longitudinal bias for the MR free layer 210. Leads 240 and 245 formed over hard bias layers 230 and 235, respectively, provide electrical connections for the flow of the sensing current I s from a current source 260 to the MR sensor 200. Fig. 3 shows a wafer 300 manufactured by Applicant's ion beam sputtering system for making SV sensors 200 . Fig. 3 illustrates schematically the general pattern of several blocks 301 , each block comprising a plurality of rows 302 . Each of the rows 302 comprises a plurality of SV sensors 200 disposed along each row and formed on the wafer substrate 306 . As mentioned earlier, Applicant conducted an experiment in which the ion beam sputtering system 120 was used to build SV sensors 200 on the wafer substrate 306 . In doing so, layers of sputtered material comprising the layer structure of the central region 202 of the SV sensor 200 were individually deposited and their uniformities were measured by measuring the sheet resistance of the film at the five positions 305 indicated on the five inch diameter of the wafer 300 . The uniformity of the sheet resistance which is representative of the film thickness uniformity across the wafer can be expressed as a percent uniformity. The percent uniformity is a measure of the maximum variation of film thickness that will be seen on a given wafer. Fig. 4 is a graph showing the normalized sheet resistance of the Cu spacer film 215 of the SV sensor 200 measured at five positions 305 across the 5 inch diameter wafer 300. For the data of Fig. 4, the Cu film thickness varied by as much as 11.3% across the wafer 300 . The sheet resistance of the NiFe and Co layers of the SV sensor 200 were also measured at the same five locations 305 across the wafer 300 . It was observed that the NiFe and Co layers' thicknesses varied by about 3.5% and 2.7%, respectively. In MR sensors the thickness of each of the thin film layers in the multilayer structure is critical to proper operation of the sensor. Variations of 11.3% in the thickness of the Cu spacer film across the wafer means that many of the MR sensors on wafer 300 fail to work properly or have unacceptably large variations in their responses. Also, as the size of the wafer increases to improve productivity, the problem of achieving film uniformity across the wafer becomes worse. The prior art does not address the need for control of the thickness uniformity of the individual thin layers deposited over the entire area of the wafer to ensure the desired device performance for an entire batch of magnetic devices fabricated with an ion beam deposition system. It would be desirable to find a technique for controlling the thickness uniformity of individual films of a multilayer thin film structure (e.g. of MR sensor) deposited on a wafer substrate in an ion beam sputtering system. According to a first aspect of the invention there is provided an ion-beam sputtering deposition system comprising: a vacuum chamber; a substrate; a target of a material; an ion beam source for directing ions at the target for depositing the material on the substrate; and a flux regulator movable relative to the substrate, for regulating the deposition of the target material onto the substrate. According to a second aspect of the invention there is provided a method of regulating the deposition of a layer of material on a substrate in an ion beam sputtering system the ion beam sputtering system having a vacuum chamber, a substrate, a target material, an ion beam source and a movable flux regulator, the method comprising the steps of: moving the movable flux regulator to a predetermined position relative to the substrate; directing ions at the target material; and depositing a portion of the target material on the substrate. Thus is disclosed an ion beam sputtering system having a movable flux regulator that affects the thickness uniformity of deposited layers across the wafer (deposition) substrate. The movable flux regulator may be usefully employed to improve the thickness uniformity of each individual layer of deposited material. The invention is advantageously employed as an ion beam sputtering deposition process for depositing MR (AMR, GMR or SV) sensors with improved thickness uniformity of each of the individual layers of the multilayer structures deposited on a wafer substrate. As is described below a flux regulator element located between the target and the substrate in an ion beam sputter deposition chamber is movable relative to the substrate in each of the three orthogonal X, Y and Z Cartesian directions. According to another embodiment the flux regulator is capable of rotation along its longitudinal axis. According to another embodiment the flux regulator is capable of swinging in a plane of a predefined axis through a predefined angle. According to yet another embodiment of the Applicant's invention, the flux regulator is capable of moving in each of the three orthogonal X, Y, and Z Cartesian directions and/or capable of rotating along its longitudinal axis and/or capable of swinging in a plane of a predefined axis. The position of the movable flux regulator relative to the deposition substrate affects the thickness uniformity of thin films deposited on the substrate by the ion beam sputtering process. The best position of the movable flux regulator for any material to be sputter deposited in a particular ion beam sputter deposition apparatus is determined by carrying out a series of depositions of that material in the system while changing the position (through X, Y, Z direction and/or rotation and or swinging) of the flux regulator for each deposition made and subsequently measuring the thickness (or a thickness dependent property such as sheet resistance) across the wafer diameter. The best position of the movable flux regulator has been found to be different for different materials deposited from different targets in the same ion beam system. Therefore, the movable flux regulator is moved to a predetermined position for each material deposited on a wafer in a multilayer structure in order to achieve improved uniformity of each deposited layer over the entire utilized wafer substrate. Applicant's movable flux regulator refers to a flux regulator whose position, relative the wafer substrate, can be changed depending on the material being deposited. As stated earlier, the fabrication of MR sensors in general and SV sensors in particular requires formation of a large number of sensors with uniform properties across the entire wafer. The uniformity of the SV sensor properties is critically dependent on thickness uniformity of each of the films deposited in these multilayer sensors. The present invention is suitable for achieving uniform properties of SV sensors across the entire wafer. Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which: Fig. 1 is a block diagram of an ion beam sputtering deposition system having fixed flux regulator; Fig. 2 is an air-bearing surface view, not to scale, of a SV sensor; Fig. 3 is a plan view of a wafer showing the general pattern of SV sensors formed on the wafer; Fig. 4 is a graph showing the variation of sheet resistance of a copper layer across a wafer fabricated using the ion beam sputtering system of Fig. 1 ; Fig. 5 is a block diagram of the preferred embodiment of an ion beam sputtering system having a movable flux regulator; Fig. 6a is a drawing showing the top view of the movable flux regulator positioned between the target and substrate in an ion beam sputtering system; Fig. 6b is a drawing showing a perspective view of the preferred shape of the movable flux regulator positioned between the target and substrate in an ion beam sputtering system; Fig. 6c is a drawing showing a perspective view of the preferred shape of the movable flux regulator positioned between the target and substrate in an ion beam sputtering system swinging through angle Θ; Fig. 7 is a graph showing the copper sheet resistance uniformity across the deposition substrate as a function of Z- setting of the movable flux regulator; Fig. 8 is a graph showing the cobalt sheet resistance uniformity across the deposition substrate as a function of Z- setting of the movable flux regulator; and Fig. 9 is a graph showing the SV sensor device sheet resistance uniformity across a deposition substrate. Referring to Fig. 5 , there is shown a partial view of the ion beam sputtering system 500 of the present invention having a movable flux regulator 550 and its positioning and control elements. The movable flux regulator 550 may also be referred to as a movable flux shaper, a movable flux modifier, a movable flux blocker or a movable flux controller or any other suitable term describing its function of moving and modifying the flux distribution incident on the substrate. The ion beam system 500 comprises a vacuum chamber 522 exhausted to a suitable low pressure by a vacuum pump (not shown) via port 535 , an ion beam source 521 directing energetic ions 533 at a target 523 of the material to be sputter deposited on a wafer substrate 531 mounted on a rotatable stage 541 . The movable flux regulator 550 , mounted on a supporting element 551 , is positioned between the target 523 and the substrate 531 so as to partially block the sputtered atom flux 526 from colliding with the substrate 531 . The flux regulator 550 of the present invention is movable relative to the substrate 531 by means of the movable supporting element (shaft) 551 which is fixed to a positioner 557 which is generally external to the vacuum chamber 522 . In the preferred embodiment, the positioner 557 is fitted with three orthogonal linear drive systems; an X-direction drive 552 , a Y-direction drive 553, and a Z-direction drive 554. The positioner 557 is also fitted with a forth drive system 555 for swinging the flux regulator 550 in the plane of a predefined axis through a predefined angle Θ (Fig. 6c ). The positioner 557 may also be fitted with a fifth drive system 556 for rotating the flux regulator along its longitudinal axis (Fig. 6b ). According to the preferred embodiment of the present invention, the drive systems are controlled by a computer system 570 programmed by software to move the flux regulator 550 to a predetermined position during a film deposition sequence. Referring now to Figs. 6a, 6b, and 6c there is shown a movable flux regulator 650 of an ion beam sputtering deposition system of the present invention in a generalized position between a target 623 and a wafer (deposition) substrate 631 . The ion beam source 621 produces an ion beam 633 that is directed to one target 623 mounted on a multiple target holder 625 . The movable flux regulator 650 is a shaped element generally located between the sputtering target 623 and the deposition substrate 631 where it is positioned for the purpose of partially blocking the sputtered atom flux 626 from the target 623 that is directed at the substrate 631 . The purpose of the movable flux regulator 650 is to modify the sputtered atom flux incident on the substrate so as to enable adjustment of the amount of material deposited across the whole wafer. Proper operation of the movable flux regulator 650 depends on the rotation of the substrate 631 about an axis perpendicular to the substrate surface 632 (Fig. 6b ). That is, the rotation of the substrate 631 is required in order to average the incident sputtered atom flux about the rotation axis of the substrate 631 . Because the incident atom flux is generally highest at the center of the substrate, the preferred shape of the movable flux regulator 650, illustrated in Fig 6b, is an arrowhead-1-ike shape whose width increases gradually from the tip 656 to a maximum width 657 and then gradually decreases (tapering off) to the width of the supporting shaft 658 . This shape results in greater blockage of the atom flux at the inner radii of the substrate 631 than at the outer radii. The fraction of the sputtered atom flux 626 blocked by the flux regulator 650 at any radial position on the substrate 631 is given approximately by the ratio of the movable flux regulator 650 width at that radius to the circumference of the substrate 631 at that radius. The shape of the movable flux regulator 650 need not be symmetric as illustrated in Figs. 6b , and 6c since only the projection of its width normal to the sputtered atom flux direction is important. The movable flux regulator 650 may also be rotated about the length axis of the mounting shaft 651 (longitudinal axis of the flux regulator) as indicated by the rotation angle  shown in Fig. 6b . As the plane of the flux regulator 650 is rotated from perpendicular to the sputtered atom flux direction, the projection of its width on the substrate surface 632 decreases resulting in blockage of less of the sputtered atom flux 626 directed at the substrate surface 631 . The movable flux regulator 650 may also swung in a plane of a predefined axis (X- axis, Y-axis or Z-axis) through a predetermined angle Θ (Fig. 6c). In the preferred embodiment of the present invention, the position of the movable flux regulator in the X-direction, Y- direction and Z-direction is adjusted for each film layer material to be sputter deposited. Experiments ran by the present inventor, fixed the X-direction and Y-direction positions of the movable flux regulator 65 0 based on the target 623 and substrate 631 geometry of the ion beam sputtering system. Specifically, in the X-direction the movable flux regulator was positioned approximately 3 cm in front of the substrate deposition surface, while in the Y-direction the movable flux regulator was positioned at the mid position 670 across the substrate diameter. Ion beam sputtering depositions of films of different materials were made with movable flux regulator Z-axis position adjusted for each material to improve the uniformity of the deposited layer of each material. Accordingly, the position of the movable flux regulator is adjusted for each material deposited in a multilayer deposition process in order to improve the uniformity of each layer deposited and the uniformity across the substrate of the combined layers forming the MR sensors. Referring now to Figs. 7 and 8 , the effects of Z-axis position of the movable flux regulator 650 are shown in graphs of the normalized sheet resistance as a function of location on the substrate for Cu and Co thin film depositions. In Fig. 7 , the Cu film uniformity improves significantly from 11.3% to 3.7% as the position of the movable flux regulator is changed from 26 mm to 24 mm in Z direction while holding the position of the movable flux regulator in X and Y directions the same. In Fig. 8 , the Co film uniformity improves from 9.0% to 2.7% as the position of the movable flux regulator is changed from 27 mm to 26 mm in Z direction while holding the position of the movable flux regulator in X and Y directions the same. Referring back to Figs. 7 and 8 , it can be seen that the Z- axis position of the movable flux regulator resulting in improved uniformity of the Cu film is different from the Z-axis position of the movable flux regulator resulting in improved uniformity of the Co film. It is this need to separately fix the flux regulator position for improved uniformity of each of the materials deposited in fabrication of multilayer films that is addressed by the movable flux regulator. An embodiment process for depositing uniform thickness layers in a multilayer structure such as SV sensors for magnetic recording devices is described herein below. An ion beam sputter deposition system as described above and illustrated in Fig. 5 is set up with multiple targets 523 on an externally rotatable support (not shown) with a separate target for each material to be deposited for the multilayer structure. For the SV sensor device described above and illustrated in Fig. 2 , deposition of the structure in the central region 202 requires targets for the AFM pinning layer, the permalloy (NiFe) for pinned MR layer and free MR layer, the Co interface layer, the Cu spacer layer and the Ru layer if the pinned layer is an AP-pinned layer. The free MR layer material is deposited using the same target as for the ferromagnetic layers of the pinned MR layer. For each target material, in order to achieve the optimum Z-axis setting of the movable flux regulator, an experiment is carried out where a set of thin films are sputter deposited on substrates using a different Z-axis setting for the movable flux regulator 550 for each film. The film thickness uniformity of each film is measured across the substrate diameter using an appropriate measure such as, for example, sheet resistance. The graphs of Fig. 7 and 8 show results obtained for Cu films and Co films. As a result of carrying out the aforementioned experiments, a setting for the Z- axis position of the movable flux regulator is chosen which achieves the highest thickness uniformity for each layer of material to be deposited on a wafer substrate. The chosen settings for the movable flux regulator are the settings that will be used during subsequent depositions of the multilayers of the MR sensors. For the computer controlled ion beam sputtering system described above, the X-axis, Y-axis, Z-axis, rotational angle  and the swing angle Θ settings may be used for each material deposition are programmed in the software program used to control the entire sputtering sequence for the multilayer deposition of the SV sensor structure. Referring now to Fig. 9 , there is shown the graph of composite sheet resistance data across the deposition substrate for the complete multilayer SV sensor of Fig. 2 including a Ta protective overlayer built according to the preferred embodiment of the present invention in an ion-beam sputtering system having a movable flux regulator. The SV layers were deposited with the settings for the Z-axis position of the movable flux regulator for each material in the structure as indicated in Fig. 9 . During this experiment, the position of the movable flux regulator was fixed in both the X and Y directions while the position of the movable flux regulator was changed in the Z direction. Using the process of the present invention, SV sensor uniformity of less than 5% was achieved over the entire utilized area of a 5 inch diameter wafer. This uniformity can be compared with the prior art RF sputtering SV structures where the uniformity is about 20-30%. The 5% uniformity of the SV sensor structure together with the excellent uniformity of the individual material depositions comprising the SV sensor provide a manufacturable process for these devices using ion beam sputtering methods utilizing the improved positioning (X, Y, Z, swinging through angle and rotation) of the movable flux regulator disclosed herein. Table I shows uniformity data for ion beam sputtered deposited SV sensors using ion beam system of Fig. 1 having a non-movable flux regulator (fixed X,Y and Z-axis positions for all the deposited layers) and the ion beam sputtering system of the present invention having a movable flux regulator where the position of the movable flux regulator in X and Y directions was fixed and its Z-axis position was optimized for each individual layer deposited. The improved uniformity, especially of the critical Cu layer, seen with the process of the present invention provides a remarkably improved manufacturing process for SV sensors on wafers. Uniformity of Deposited Layers Material Z-Setting (mm) Uniformity (%) Non-Movable Flux Regulator NiFe 26 3.5 Co 26 2.7 Cu 26 11.3 Movable Flux Regulator NiFe 26.5 1.2 Co 26 2.7 Cu 24 3.7 While the present invention has been particularly shown and described with reference to the preferred embodiment thereof, nevertheless, it will be understood by those skilled in the art that various modifications may be made therein without departing from the scope of the present invention. For example, a positioning method different from the X, Y, Z Cartesian system, swinging through angle Θ and rotation described herein may be used to achieve equivalent results. For example a positioning system for the movable flux regulator based on a polar coordinate system motions could be employed. Furthermore, although the ion beam system of the present invention was mainly utilized to improve thickness uniformity of each deposited layer across an MR sensor wafer, the invention is equally applicable to any art that may benefit from improved thickness uniformity of an ion beam sputter deposited layer on a substrate.

Claims: An ion beam sputtering deposition system including a vacuum chamber (522), a support (541) for a substrate (531), a further support for a target (523) of a material, an ion beam source (521) for directing ions (533) at the target for producing a sputtered flux of the material (526) for depositing onto the substrate, and a flux blocker (550) positioned between the target and the substrate for partially blocking the sputtered flux, characterised in that the system further includes control means (570,557) for moving the flux blocker relative to the substrate for regulating the quantity of material deposited across the substrate. The ion beam sputtering deposition system according to claim 1, wherein the flux blocker includes an arrowhead-like shaped element (650) for providing a greater blockage of the sputtered flux at an inner radial region of the substrate (631). The ion beam sputtering deposition system according to claim 1 or 2, wherein the control means includes drive systems (552,553,554) for rotating the flux blocker along at least one of the X-axis, Y-axis and Z-axis directions. The ion beam sputtering deposition system according to claim 3, wherein the control means includes a drive system (555) for swinging the flux blocker in a plane of a predefined axis. The ion beam sputtering deposition system according to claim 4, wherein the control means includes a drive system (556) for rotating the flux blocker along a longitudinal axis thereof. The ion beam sputtering deposition system according to any claim from 1 to 5, wherein the control means (570,557) includes means (570) for storing a preferred position of the flux blocker (550) for each one of a plurality of targets of differing materials and for positioning the flux blocker at the stored position corresponding to an active target. The ion beam sputtering deposition system according to claim 6, wherein the further support is a multiple support (625) for holding the plurality of targets of differing materials. The ion beam sputtering deposition system according to claim 7, further including a rotatable stage for rotating the multiple support (625) for selecting the active target. The ion beam sputtering deposition system according to any claim from 6 to 8, wherein the materials of the targets are chosen from copper, cobalt, Ni-Fe, NiMn, NiO, Ni and Ru. A method of operating a ion beam sputtering deposition system comprising the steps of: providing a substrate on a support inside a vacuum chamber, providing a target of a material on a further support inside the chamber, directing ions at the target for producing a sputtered flux of the material for depositing onto the substrate, providing a flux blocker positioned between the target and the substrate for partially blocking the sputtered flux, characterised by the step of moving the flux blocker relative to the substrate for regulating the quantity of material deposited across the substrate. The method according to claim 10, wherein the system stores a preferred position of the flux blocker for each one of a plurality of targets of differing materials and wherein the further support is a multiple support for holding the plurality of targets of differing materials, the method further comprising the steps of selecting in sequence an active target from the plurality of targets and positioning the flux blocker at the stored position corresponding to the active target before directing ions at the active target. A method of manufacturing a multilayer thin film structure using a ion beam sputtering deposition system, the method comprising the steps of: providing a wafer substrate on a support inside a vacuum chamber, providing a plurality of targets of differing materials on a multiple support inside the chamber, each material corresponding to a layer of the structure, and for each layer of the structure: selecting an active target of the corresponding material, directing ions at the active target for producing a sputtered flux of the material for depositing onto the substrate, characterised in that the system stores, for each target of differing materials, a preferred position of a flux blocker, the flux blocker being positioned between the active target and the substrate for partially blocking the sputtered flux and being movable relative to the substrate for regulating the quantity of material deposited across the substrate, the method further including the step of moving the flux blocker at the stored position corresponding to the active target before directing ions at the active target.

Inventors: PINARBASI MUSTAFA, PINARBASI, MUSTAFA
Applicants: IBM, INTERNATIONAL BUSINESS MACHINES CORPORATION
Application year: 1998
Main classification: C23C14
IPC codes: C23C14