Patent ID: 7712514

Claim:
A method of making an aluminum or aluminum alloy sputter target adapted for sputtering of a flat panel display comprising: (a) determining a power density at which said flat panel display will be sputtered; (b) correlating said determined power density from said step (a) to a threshold value for deleterious sputter target inclusion sizes; (c) providing molten Al or Al alloy; (d) adding to said molten Al or Al alloy an amount of between about 0.01-2.00 wt % Si and from about 0.01-3.00 wt % Cu to form a molten alloy mixture; (e) forwarding said molten alloy mixture through a filter and choosing a filter grit size of between about 2 to about 14 to filter from said molten alloy inclusions having sizes greater to or equal to said threshold value; and (f) allowing said filtered alloy to solidify and forming said target; whereby said target is substantially free of inclusions having sizes greater to or equal to said threshold value.