AlGaN films were grown on face-to-face annealed sputter-deposited AlN/sapphire (FFA Sp-AlN) templates via metalorganic vapor phase epitaxy (MOVPE), and the growth behavior of the AlGaN films was investigated. The sapphire substrates with small off-cut exhibited poor surface flatness of AlGaN grown on the FFA Sp-AlN templates owing to the formation of large hillock structures. To understand the origin of these hillock structures, the crystallinity and surface morphology of conventional fully MOVPE-grown AlN/sapphire (MOVPE-AlN) templates and the FFA Sp-AlN template were comprehensively studied. The screw- and mixed-type threading dislocation density of the FFA Sp-AlN template was estimated to be approximately 1.8 × 106 cm−2, which was two orders of magnitude lower than that of the MOVPE-AlN template. Consequently, the uniquely observed growth of the hillock structures in the FFA Sp-AlN templates was attributed to their low density of screw- and mixed-type threading dislocations. The large surface off-cut sapphire substrates suppressed the hillock structures on the FFA Sp-AlN templates. The improvement in surface flatness resulted in better optical properties of multiple quantum wells grown on the AlGaN layer. These results demonstrate a promising method for achieving highly efficient and cost effective AlGaN based deep ultraviolet light-emitting diodes.

Combination of sputter deposition and high-temperature annealing is a promising technique for preparing AlN templates with a low threading dislocation density (TDD) at a lower film thickness compared to those prepared by the conventional metalorganic vapor phase epitaxy. However, cracking of AlN films during annealing is a critical issue. In this study, we controlled the residual stress of the sputter-deposited AlN films by modifying the sputtering conditions. Consequently, the occurrence of cracking was effectively suppressed. By optimizing the fabricating conditions, a TDD of 2.07 × 108 cm−2 was achieved for the AlN template with a thickness of 480 nm.

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AlN on sapphire with dislocation density of 107 cm−2 was prepared by double sputtering and annealing processes. Full width at half maximum values of X-ray rocking curve for and diffractions of the AlN films were measured to be 10–20 arcsec and 65–82 arcsec, respectively. Dislocations were characterized by plan-view and cross-sectional transmission electron microscopy, and the total dislocation density was estimated as 4.3 × 107 cm−2. A polarity inversion layer was found between the two sputtered AlN layers, which increased the possibility of blocking dislocations stemming from the AlN/sapphire interface.

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