Abstract:
A method to provide an article of manufacture of iron oxide on indium tin oxide for solar energy conversion. An atomic layer epitaxy method is used to deposit an uncommon bixbytite-phase iron (III) oxide (β-Fe 2 O 3 ) which is deposited at low temperatures to provide 99% phase pure β-Fe 2 O 3  thin films on indium tin oxide. Subsequent annealing produces pure α-Fe 2 O 3  with well-defined epitaxy via a topotactic transition. These highly crystalline films in the ultra thin film limit enable high efficiency photoelectrochemical chemical water splitting.

Description:
STATEMENT OF GOVERNMENT RIGHTS 
     The United States Government claims certain rights in this invention pursuant to Contract No. DE-AC02-06CH11357 between the United States Government and UChicago Argonne, LLC representing Argonne National Laboratory. The United States Government also claims certain rights in this invention pursuant to research sponsored by the Army Research Lab, ANL Cost Code 8R26900. 
    
    
     FIELD OF THE INVENTION 
     The invention is directed to an improved process and article of manufacture for solar energy conversion. More particularly, the invention is directed to a method to produce an atomic layer epitaxy of hematite on indium tin oxide to carry out photochemical water splitting. 
     BACKGROUND OF THE INVENTION 
     Of the reported phases of iron oxide, only hematite (α-Fe 2 O 3 ) is considered a promising anode material for photoelectrochemical (PEC) oxidation of water for application in solar fuel production. Indeed, α-Fe 2 O 3  possesses a suitable band gap and alignment for solar absorption and the O 2  evolution reaction of water, is terrestrially abundant and inexpensive, and is stability in aqueous, and is therefore considered one of the most attractive options. Within the last 10 years, the improved quality and nanoscale control of α-Fe 2 O 3  photoanodes has spurred a series of record-breaking efficiencies. However, the major limiting factors of hematite is the high recombination rate of photo-generated charge carriers combined with the relatively weak absorption of light, as well as slow water oxidation kinetics at the α-Fe 2 O 3  surface. This means less than 50% of visible light is absorbed within the space-charge layer and can contribute to PEC water splitting. While efforts have been made to improve the intrinsic charge-transport and oxidation kinetic properties of α-Fe 2 O 3  by means of doping and surface modification, α-Fe 2 O 3  may be limited by these properties. While it is difficult to find the same beneficial combination of photoanode properties in other semiconducting materials, it is possible that alternate iron oxide polymorphs may exhibit superior behavior. 
     Phoelectrochemical investigations of the other reported iron oxide phases, which include Fe 1-x O, β-Fe 2 O 3 , γ-Fe 2 O 3 , ε-Fe 2 O 3 , and Fe 3 O 4 , have been largely overlooked in favor of research on α-Fe 2 O 3 . This stems from the fact that these polytypes are either metastable and difficult to synthesize in useful forms (β-Fe 2 O 3  and ε-Fe 2 O 3 ), or have not demonstrated significant photoactivity (Fe 1-x O, γ-Fe 2 O 3 , Fe 3 O 4 ). The β-Fe 2 O 3  polymorph, which is our focus here, has no reported natural occurrence and as of yet has found little application. It has been synthesized as a polycrystalline thin film on only a handful of occasions by using iron trifluoroacetylacetone as an iron source in chemical vapor deposition and spray pyrolysis. More commonly, it has been produced as nanoparticulate form via hydrolysis of FeCl 3 , solid-state reaction of NaCl and Fe 2 (SO 4 ) 3 , or via thermal decomposition of Fe(C 10 H 9 CHO) or FeSO 4  in mesoporous SiO 2 . While monophasic nanoparticles of β-Fe 2 O 3  have been reported, it appears that all β-Fe 2 O 3  thin films fabricated to date have been mixed-phase. 
     β-Fe 2 O 3  possesses a bixbyite-type crystal structure (space group Ia 3 ) with lattice parameter a=9.40. β-Fe 2 O 3  is thermodynamically unstable, with reports of transformation to either α-Fe 2 O 3  or γ-Fe 2 O 3  upon heating, depending on the morphology and annealing conditions. While pure hematite is a canted antiferromagnet or weak ferromagnet at room temperature, β-Fe 2 O 3  is paramagnetic at room temperature. 
     There is therefore a substantial need for an improved article of manufacture to provide highly efficient solar energy conversion for photochemical oxidation of water and which can be efficiently and rapidly manufactured. 
     SUMMARY OF THE INVENTION 
     Epitaxial, isomorphic stabilization of bixbyite-phase iron(III) oxide (β-Fe 2 O 3 ) is obtained by atomic layer deposition (ALD) at low temperatures, such as about 200° C., on an epitaxial tin-doped indium oxide (ITO) thin film template. X-ray diffraction measurements verify the growth of majority phase β-Fe 2 O 3  thin films with cube-on-cube epitaxy with respect to the low-index [(100), (110), and (111)] epitaxial ITO/YSZ template. As-grown films are &gt;99 vol % β-Fe 2 O 3 , and only Fe 2 O 3  films grown on ITO/YSZ(100) show evidence of minority α-phase. Cross-sectional transmission electron microscopy verifies an atomically sharp interface, and atomic force microscopy finds a smooth thin film morphology consisting of 200×200 nm 2  grains. Absorption spectroscopy reveals an β-Fe 2 O 3  band gap of (1.85 eV), which is ˜0.2 eV smaller than that typically observed for hematite α-Fe 2 O 3 . Cyclic voltammetry of the unannealed β-Fe 2 O 3  thin film photoanodes reveal improved current densities and cathodically-shifted onset voltages of for all β-Fe 2 O 3  epitaxial permutations with respect to fired randomly-oriented α-Fe 2 O 3 /ITO/YSZ counterparts. Finally, the epitaxial stabilization of the β-Fe 2 O 3  induces crystallinity within even the thinnest fabricated films (5 nms), suggesting a route for fabrication of ultrathin Fe 2 O 3  absorbers. 
     These and other advantages and features of the invention, together with the organization and manner of operation thereof will become apparent from the detailed description that follows when taken in conjunction with the accompanying drawings described below. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         FIGS. 1 a -1 c    show a schematic illustration of the idealized epitaxial β-Fe 2 O 3  photoanode grown on low-index YSZ: a) YSZ(001), b) YSZ(011), and c) (111); 
         FIGS. 2 a -2 c    are directed to diagrams of heterostructures on various orientations of YSZ and  FIGS. 2 d -2 f    show corresponding out of plane thin film X-ray diffraction measurements, respectively; and  FIGS. 2 g -2 i    are associated pole figures with inset simulation of the heterostructure; 
         FIGS. 3 a -3 c    show Raman spectra for low-index-oriented β-Fe 2 O 3 /ITO/YSZ photoelectrodes taken with 633 nm laser light. Peaks denoted with * are attributed to β-Fe 2 O 3 , no signal from α-Fe 2 O 3 , (denoted with |) are observed. Increase in background makes these signal unobservable in A;  FIGS. 3 d -3 f    show AFM images for all three samples; formation of large (˜50 nm heights) particulate islands are observable in D, while smoother films (RMS=˜5 nm) in E and F consist of relatively smaller gains (20 nm lateral dimensions); 
         FIG. 4  shows current-voltage measurements in dark (dotted line) and in light (solid line) for low-index-oriented β-Fe 2 O 3 /ITO/YSZ photoelectrodes. All films are photoactive as grown; and 
         FIG. 5 a - c    show pole figures for the α-Fe 2 O 3  specimens on various orientations of YSZ after annealing the heterostructures in  FIG. 2 a - c    with inset simulation of the new heterostructure. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Epitaxial β-Fe 2 O 3  thin films have been grown on low-index [(100)-, (100)-, and (111)-oriented] yttria-stabilized zirconia (YSZ) substrates atomic layer deposited (ALD) indium tin oxide (ITO) (see  FIGS. 1 a -1 c   ). After annealing the YSZ for 3 hours at 1100° C. to achieve flat, terraced substrate surfaces. Prior to ITO deposition the substrates were cleaned with and acetone and isopropanol rinse, followed by an O 3  clean. ITO was deposited using a conventional method using cyclopentadienylindium(I) and tetrakis(dimethylamido)tin as metal precursors and ˜5 wt % O 3  in O 2  as the oxidant. During deposition the ALD reactor chamber was held at to 250° C. The InCp-O 3  dose sequence was t 1 -t 2 t 3 t 4 =1-10-0.1-10, where t 1  and t 3  are the metalorganic and ozone dose times, respectively, and t 2  and t 4  are the purge times, reported in seconds. Every tenth ALD cycle was swapped to the TDMASn-O 3  dose sequence of 0.5-10-0.1-10. In total, 14 supercycles of 9:1 In 2 O 3 :SnO 2  were completed, yielding ITO thin films of ˜20 nms. ALD was performed of Fe 2 O 3  using ferrocene Fe(Cp) 2  and O 3 . The dose sequence of t 1 -t 2 -t 3 -t 4 =60-35-90-20. Both Fe(Cp) 2  and O 3  doses were run using quasi-static exposure to complete oxidation and allow substrate temperatures to remain at about 200° C. An exposure sequence t 1 -t 2 -t 3 -t 4 =2×(2-28)-5-90-30 for 300 cycles ensures saturating and self-limiting growth. The Fe(Cp) 2  dosing was performed in quasi-static mode, in which a two second precursor dose was followed by a 28 second exposure. The Fe(Cp) 2  does was performed twice per cycle. 
     Diffraction measurements, used to identify phase and epitaxy, were performed at sectors 13-BM-C and 33-BM-C at the Advanced Photon Source, Argonne National Laboratory. Samples were mounted under kapton and He was flowed during the duration of the measurement. 15.0 keV (wavelength λ=0.826 Å −1 ) X-rays were focused to a 0.5 mm vertical×2 mm horizontal spot at the detector position, and scattered X-rays were collected using a Pilatus 100K area detector. 
       FIGS. 2 a -2 c    show diagrams of the β-Fe 2 O 3 /ITO/YSZ heterostructures;  FIGS. 2 d -2 f    show out-of-plane thin-film X-ray diffraction measurements for all samples. No sample exhibits diffraction associated with an a-Fe 2 O 3  phase, and only b-Fe 2 O 3  reflections of the same family as the epitaxial ITO are observable, suggesting cube-on-cube epitaxy. Thin film modulation in each scan are a testament to the smooth, uniform thin film character; the  FIGS. 2 g -2 i    show X-ray pole figures at a |q| range of =2.16-2.72 Å −1  encompassing a d-spacing range including only the α-Fe 2 O 3 {1014}, β-Fe 2 O 3 {222}, ITO{123} family of reflections. 
     The epitaxial orientation of β-Fe 2 O 3  crystallites and presence of α-Fe 2 O 3  within the films was determined by the above described X-ray pole figures. The use of a 2D X-ray detector enabled the simultaneous collection of reflections satisfying Bragg conditions between G hkl =2π/d hkl  q=2.15-2.65 Å −1  at each diffractometer colatitude angle χ and azimuthal angle φ (for details, see Refs.). Here, G hkl  is the hkl reciprocal lattice point, d hkl  is the YSZ lattice spacing, and q=4π Sin(2θ/2)/λ is the momentum transfer. The data can then be reconstructed as a cylindrical volume where each slice along the longitudinal axis corresponds to a range of d-spacings. 
     The above described pole images show intensity (exponentiated by 0.2) integrated from q=2.28-2.34 Å −1  (d=2.68-2.80 Å): a range which includes only the ITO{123}[19], α-Fe 2 O 3 {10 14 , β-Fe 2 O 3 {222} families of reflections. In each figure the β-Fe 2 O 3 {222} reflections are circled while the weaker ITO(123) are left unindexed. In each case the β-Fe 2 O 3 {222} reflections are positioned at the same χ and φ values as the YSZ(111) and ITO(222) reflections, verifying the (001) β-Fe     2     O     3   ∥(001) ITO ∥(001) YSZ  and [001] β-Fe     2     O     3   ∥[001] ITO ∥[001] YSZ  epitaxial relationship for all substrates, as indicated by the θ/2θ scans. 
     A weak set of reflections were indexed (indicated by radially displaced white dots) positioned at χ=38.X° which is 12-fold symmetric in φ. This corresponds to a minority phase of α-Fe 2 O 3  that possesses two crystallographically equivalent orientations with respect to the ITO. We note that while the calculated intensity from the β-Fe2O3 and α-Fe2O3 are within a factor of three or each other, the strength of the β-phase peaks are greater three orders of magnitude that of the α-phase, indicating that &lt;1% of the film consists of α-Fe 2 O 3 . 
     Raman spectra shown in  FIGS. 3 a -3 c    were acquired over a range of 100-800 cm −1  using a Renishaw inVia spectrometer equipped with a 17 mW He—Ne laser passing 632.8 nm unpolarized light through an 50× objective lens. The associated microstructure are in  FIGS. 3 d -3 f   . The scattered light was collected in a back-scattering geometry with an 1800 lines/mm grating and a CCD camera. These are Raman spectra for the Fe 2 O 3 /ITO stacks which were grown on each low-index YSZ substrate, as well as ITO/YSZ and YSZ control spectra. In each case, the bare YSZ Raman spectrum possesses a dominant signal near 610 nm −1  typically assigned to the F 2     g    phonon mode. The spectra ITO-coated YSZ substrates are identical to the bare YSZ spectra in all cases apart from an increase in lower-frequency intensity for ITO grown on the (100)-oriented YSZ. No evidence was observed of the allowed ITO Raman modes, likely because of the dominance of the broad YSZ spectrum, as well as the chosen excitation wavelength (λ=632.8 nm), which is far from the optical phonon resonance for ITO. The iron oxide films grown on ITO(110)∥YSZ(110) and ITO(111)∥YSZ(111) show peaks associated with β-Fe 2 O 3  that agree well with the strongest of those reported in the art. For the iron oxide grown on ITO(100)∥YSZ(100) we observe no β-Fe 2 O 3  peaks, but instead a broad, largely uniform increase in the Raman scattering across the spectrum. While the source for this increase in scattering is unclear, it is possible that it is washed out by this increase in background signal. Regardless, no spectra indicate the presence of any α-Fe 2 O 3 , and this data, together with the phase identification from X-ray diffraction, verify our identification of β-Fe 2 O 3  films. 
     β-Fe 2 O 3  films have not previously been fabricated in phase-pure form, and therefore have not been investigated as an anode material for photoelectrochemical water splitting. The associated photocurrent density, J sc  vs potential for all three unannealed epitaxial thin film stacks is shown in  FIG. 4 . These data are compared to two co-deposited baseline samples: 1.) an as-deposited Fe 2 O 3 /ITO/fused quartz sample and 2.) a Fe 2 O 3 /ITO/fused quartz sample that was annealed at 500° C. in 250 sccm O 2 . As is typical of unfired ALD Fe 2 O 3  samples, the unfired Fe 2 O 3 /ITO/fused quartz shows no photoactivity. 
     The following Examples illustrate a non-limiting description of methods used in the invention and methods of characterization. 
     Example I 
     Single crystal YSZ(111) samples were annealed at 1100° C. in 250 sccm high-purity O 2  to obtain a smooth, terraced (100 nm) surface. Samples were then sonicated in acetone, followed by isopropyl alcohol for 10 minutes each. After each sonication the substrates were dried with N 2 . Samples were loaded into the ALD chamber at 250° C. and allowed to thermally equilibrate for 30 minutes before a 180 s ozone (O 3 ) clean. 
     ALD was performed using a Cambridge Nanotech, Inc. Savannah 200 ALD reactor. Dose duration sequences of t 1 -t 2 -t 3 -t 4  were used, where t 1  and t 3  are dose times (in seconds) for the metal and ozone precursors, respectively, while t 2  and t 4  are the corresponding purge times. ITO was grown based on the process developed by Elam et at [14]. Cyclopentadienylindium(I) (InCp, 99.99%, Strem) and tetrakis(dimethylamido)tin (Sn(NMe 2 ) 4 , 99.99%, Aldrich) were used as metal precursors during ITO growth, and ozone was provided in 5 wt % in 100 sccm high-purity O 2  using a DelOzone generator. During deposition the Sn(NMe 2 ) 4  and InCp precursors were held to 55 and 70° C., respectively. The reactor chamber was heated to 250° C. The InCp-O 3  dose sequence was 1-10-0.1-10, and every tenth cycle was switched to TDMASn-O 3  dose sequence of 0.5-10-0.1-10. In total, 14 supercycles of 9+1 In 2 O 3  and SnO 2  were completed, yielding ITO thin films of 20 nms, as measured by X-ray reflectivity (Phillips X&#39;pert Pro MRD). The average growth rate per cycle was 1.4 Å/cycle, which is comparable to values reported in the prior art. Hall measurements (HMS-3000) in the van der Pauw geometry gave sheet resistances of ˜4×10 −4  Ω/sq. Fe 2 O 3  was grown using ferrocene (Fe(Cp) 2 , 98%, Aldrich) and O 3 , using a dose sequence of 60-35-90-20. During Fe 2 O 3  growth, both Fe(Cp) 2  and O 3  doses were run using quasi-static exposure. 
     X-ray pole figures and reciprocal space maps were acquired at beamline 33-BM-C at the Advanced Photon Source, Argonne National Laboratory. Samples were mounted under kapton and He was flowed during the duration of the measurement. 15.0 keV (wavelength=0.826 Å −1 ) X-rays were focused to a 0.5 mm vertical×2 mm horizontal beam, and scattered X-rays were collected using a Pilatus 100K area detector (Dectris). The use of the 2D detector enabled the simultaneous collection of reflections which satisfied the Bragg condition G hk(i)l =2π/d hk(i)l =q=2.1-2.4 Å −1  at each diffractometer angle χ and φ [21], where G hk(i)l  is the hk(i)l reciprocal lattice point, d is the hk(i)l planar spacing, and q is the momentum transfer. The resolution in q was limited to 0.001 Å −1  due to the detector pixel size of Q. Further structural information was accessed using transmission electron microscopy. 
     Example II 
     Photoelectrochemical (PEC) current-voltage measurements were performed in 0.1 M KOH (pH 13.1) using a CHI10E potentiostat. Measurement were conducted using a three electrode configuration, with Ag/AgCl and Pt as reference and counter electrodes, respectively. PEC data was normalized by the sample surface area exposed to the electrolyte (0.2 cm 2 ). The AM1.5 solar spectrum was simulated using 300 W arc lamp, calibrated to 100 mW/cm 2  using a silicon photodiode. 
     Raman spectra were acquired over a range of 100-1000 cm −1  using a Renishaw Ramascope spectrometer equipped with a 632.8 nm He—Ne laser. Data were collected with a 50× objective lens at 100% laser power. Collection time for each spectra was 30 s. 
     Example III 
     X-ray diffraction was used to verify the phase and epitaxial relationship between the Fe 2 O 3  and underlying cube-on-cube ITO(111)∥YSZ(111) template.  FIG. 2 f    presents the specular scan along the YSZ[111], where q n =4π Sin (2θ/2)/λ, where 2θ is the scattering angle. For YSZ and ITO, only allowed reflections from the {111] families are observed. For Fe 2 O 3 , no reflections from commonly observed Fe 2 O 3  phases (α-Fe 2 O 3 , Fe 3 O 4 ) are observable ( FIG. 2 f   ). 
     Example IV 
     Production of epitaxial β-Fe 2 O 3  on ITO/YSZ is produced from the β-Fe 2 O 3  heteroepitaxial structures by thermal processing. All low-index β-Fe 2 O 3 /ITO/YSZ starting samples (see  FIG. 5 a   ) were heated to 750° C. in 0.25 sccm O 2  for 2 hrs, and pole figure measurements were repeated to probe phase and preferred crystallite orientation. Upon annealing, we found that the diffraction peaks attributed to the epitaxial β-Fe 2 O 3  film of  FIG. 5 a    were no longer present, and new peaks indexed to α-Fe 2 O 3  appeared. For α-Fe 2 O 3 /ITO/YSZ(100), a 12-fold symmetric ring of α-Fe 2 O 3 (1014) reflections formed, as is expected geometrically for a 3 m hexagonal epilayers with rotationally twinned domains sitting atop a 4 mm symmetric substrate. This epitaxial relationship is defined as [0001]α-Fe 2 O 3 ∥ITO[001]∥YSZ[001] along the surface normal and &lt;1120&gt;∥(100) in-plane. This epitaxial relationship is maintained universally for both α-Fe 2 O 3 /ITO/YSZ(110) and α-Fe 2 O 3 /ITO/YSZ(111). This epitaxy is dictated by the original β-Fe 2 O 3 /ITO/YSZ epitaxy, and the transition is found to proceed topotactially, as is observed in the nanoparticulate β-Fe 2 O 3  form. Interfacial strain is mitigated by small (a few degrees), symmetric α-Fe 2 O 3  domain tilts about the [110] axes of the YSZ, as observed in the pole figures (see  FIGS. 5 a -5 c   ). 
     The foregoing description of embodiments of the present invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the present invention to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from practice of the present invention. The embodiments were chosen and described in order to explain the principles of the present invention and its practical application to enable one skilled in the art to utilize the present invention in various embodiments, and with various modifications, as are suited to the particular use contemplated.