Phase formation in Fe–Si thin-film diffusion couples
The formation of FeSi2, as well as other iron silicides, from solid-state reactions of Fe thin films on Si substrates has been investigated. Iron layers, approximately 50 nm thick, were deposited by electron beam evaporation on <100> oriented Si substrates. Silicon (≈35 nm) and SiO2 (≈170 nm) layers were deposited on top of the Fe layer in the same evaporator without breaking the chamber vacuum. SiO2 acted as a protective layer during subsequent annealing in a nitrogen ambient. All annealed samples were examined using X-ray diffraction and transmission electron microscopy (TEM). Both plan view and cross section specimens were prepared for TEM. Detailed phase analysis was accomplished through the various electron diffraction and X-ray microanalysis techniques available with the TEM. Silicon dissolved readily in Fe, at temperatures lower than 300 °C, up to the solubility limit of ≈26 at%Si. FeSi formation followed (350 °C), with semiconducting FeSi2 forming at 500 °C. The Fe–amorphous Si interface was more reactive, with silicide formation occurring at lower annealing temperatures (300 °C). There was also evidence that FeSi2 formed directly from α-Fe and amorphous Si.