A method of forming crystalline tungsten carbides was
reported
by exposing the heated tungsten filament to 1,1,3,3-tetramethyl-1,3-disilacyclobutane
(TMDSCB) in a hot-wire chemical vapor deposition process. Methyl radicals
produced from the decomposition of TMDSCB on the filament serve as
the carbon source. The formation of tungsten carbides was investigated
by X-ray diffraction, cross-sectional scanning electron microscopy,
and in-situ filament resistance measurements. A pure W2C phase was formed at a high temperature of 2400 °C after 1–2
h exposure time with a growth rate of 4.4 μm min–1. The growth of the W2C layer is found to be a diffusion-controlled
process. Our study at longer deposition time of 3–4 h shows
that once the metal filament is fully carburized to form W2C, the carbon-rich WC phase starts to form on the outside layer upon
further exposure to TMDSCB. A WC layer with no contamination from
the W2C phase was found to be formed at 2400 °C and
4 h deposition time.