Patent ID: 8425681

Claim:
A method for making reduced-dislocation-density material, comprising: applying at least one monolayer of spheroidal particles to a substrate comprising a base substrate and a first layer of growth material, the at least one monolayer having interstices between the spheroidal particles oriented to permit access of reactant gases to the first layer of growth material; initiating growth of a second layer of growth material at sites on the first layer of growth material that are exposed to reactant gases through the interstices; growing the growth material through the interstices; terminating adjacent to the spheroidal particles a plurality of threading dislocations propagating through the growth material; coalescing the growth material growing through adjacent interstices to embed the at least one monolayer of spheroidal particles within the second layer of growth material to form a second layer of growth material with reduced dislocation density; applying a second at least one monolayer of spheroidal particles atop the second layer of growth material, the second at least one monolayer having a second set of interstices between the spheroidal particles oriented to permit access of reactant gases to the second layer of growth material; initiating growth of a third layer of growth material at sites on the second layer of growth material that are exposed to reactant gases through the second set of interstices; growing the growth material through the second set of interstices; and coalescing the growth material growing through adjacent interstices to embed the second at least one monolayer of spheroidal particles within the third layer of growth material to form a third layer of growth material with reduced dislocation density.