Electrochemical Atomic Layer Deposition of Cobalt Enabled by the Surface-Limited Redox Replacement of Underpotentially Deposited Zinc

Abstract

Electrochemical atomic layer deposition (e-ALD) process for fabricating cobalt (Co) nano-films is reported. The e-ALD process employs a two-step approach in which underpotential deposition (UPD) is first used to form a sacrificial adlayer of zinc (Zn) on a ruthenium (Ru) substrate. The sacrificial Zn adlayer then undergoes spontaneous surface-limited redox replacement (SLRR) by nobler Co. This provides an atomic layer of Co on the substrate surface. The two-step process is repeated cyclically to build multilayers of Co. The unique feature of the e-ALD approach presented herein is that it utilizes Zn as the sacrificial adlayer instead of Pb or Cu used conventionally in the e-ALD sequence of noble metals. The use of sacrificial Zn uniquely renders its redox replacement by Co to be thermodynamically favorable, thereby enabling Co e-ALD. In the present report, we discuss the electrochemical characteristics of the UPD and SLRR process steps, the e-ALD deposition rate and the deposit surface roughness. The Co deposits formed via e-ALD do not exhibit roughness amplification during the first 10 cycles of e-ALD, which is indicative of atomic-scale layer-by-layer growth of Co on the underlying Ru substrate.