Semiconductors are commonly etched with two techniques: "Wet" etching uses a chemical solution to erode the semiconductor in all directions, while "dry" etching uses a directed beam of ions to bombard the surface, carving out a directed pattern. Such patterns are required for high-aspect-ratio nanostructures, or tiny shapes that have a large ratio of height to width. High-aspect-ratio structures are essential to many high-end optoelectronic device applications.
While silicon is the most ubiquitous material in semiconductor devices, materials in the III-V (pronounced three-five) group are more efficient in optoelectronic applications, such as solar cells or lasers. Unfortunately, these materials can be difficult to dry etch, as the high-energy ion blasts damage the semiconductor's surface. III-V semiconductors are especially susceptible to damage.
To address this problem, electrical and computer engineering professor Xiuling Li and her group turned to metal-assisted chemical etching (MacEtch), a wet-etching approach they had previously developed for silicon. Unlike other wet methods, MacEtch works in one direction, from the top down. It is faster and less expensive than many dry etch techniques, according to Li. Her group revisited the MacEtch technique, optimizing the chemical solution and reaction conditions for the III-V semiconductor gallium arsenide (GaAs).
The process has two steps. First, a thin film of metal is patterned on the GaAs surface. Then, the semiconductor with the metal pattern is immersed in the MacEtch chemical solution. The metal catalyzes the reaction so that only the areas touching metal are etched away, and high-aspect-ratio structures are formed as the metal sinks into the wafer. When the etching is done, the metal can be cleaned from the surface without damaging it.
A scanning electron microscope image of "nanopillars" etched in gallium arsenide via metal-assisted chemical etching. Credit: Xiuling Li
"It is a big deal to be able to etch GaAs this way," Li said. "The realization of high-aspect-ratio III-V nanostructure arrays by wet etching can potentially transform the fabrication of