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Applied Surface Science 255 (2009) 6479–6486

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Applied Surface Science


journal homepage: www.elsevier.com/locate/apsusc

Effect of sputtering parameters on surface morphology and catalytic


efficiency of thin platinum films
E. Slavcheva a,b,*, G. Ganske a, G. Topalov b, W. Mokwa a, U. Schnakenberg a
a
Institute of Materials in Electrical Engineering I, RWTH, Aachen University, 52074 Aachen, Germany
b
Institute of Electrochemistry and Energy Systems, Bulgarian Academy of Sciences, 1113 Sofia, Bulgaria

A R T I C L E I N F O A B S T R A C T

Article history: This paper presents a research on the influence of sputtering parameters (dc power, argon pressure) and
Received 2 September 2008 film thickness/metal loading on the surface structure and morphology of platinum thin films and their
Received in revised form 2 February 2009 catalytic activity toward the oxygen reduction in acid aqueous solutions. The properties of the sputtered
Accepted 4 February 2009
films were studied using scanning electron microscopy (SEM), X-ray diffraction (XRD), and the
Available online 21 February 2009
electrochemical methods of cyclic voltammetry and steady state polarisation. It was found that low
sputtering power and high sputtering pressure lead to deposition of mechanically stable crystalline Pt
Keywords:
films with extended surface area. Optimal sputtering parameters of 68 mTorr argon pressure and 100 W
Sputtered Pt films
dc power were determined. The films deposited at these conditions possess homogeneous, highly
Electrocatalysis
Oxygen reduction developed surface with columnar structure. The increase in thickness results in essential epitaxial
growth of the platinum particles with distinct [1 1 1] orientation. The best utilization of the catalyst
(1.103 A cm2 nmPt1 mass activity determined from the polarisation curves at 0.4 V) was achieved at
120–130 nm film thickness.
ß 2009 Elsevier B.V. All rights reserved.

1. Introduction catalyst loadings [1–6]. Experimental data reported recently have


shown that the electrochemical behaviour of sputtered metal and
The plasma enhanced physical vapour deposition (PVD) metal oxide films depends essentially on the chosen deposition
method of magnetron sputtering is a well established technique conditions [7–11]. It has been proven that by variation of the
broadly used in the field of silicon micro- and nano-technologies sputter parameters such as dc or rf power, inert and reactive gas
for deposition of thin metal, oxide, and composite films with flow, partial pressure, temperature, distance between the target
specific applications. In the last years the method is gaining and the substrate, etc. it is possible to modify not only the film
increasing interest in the field of electrocatalysis. Several research composition, but also its structure and morphology and thus, to
groups introduced it as an alternative of the conventional catalysts tailor the specific surface and the electrochemical reactivity. For
preparation techniques, particularly for application in the energy instance, we have shown previously [7,12] that by varying just the
conversion electrochemical cells with polymer membrane elec- oxygen partial pressure during the reactive dc sputtering of
trolytes (fuel cells, water electrolysers, and unitized regenerative iridium oxide, the roughness of the deposited film can be increased
fuel cells). The method offers a variety of advantages compared to more than one order of magnitude which in turn, amplifies the
the common methods for catalysts preparation such as wet charge transfer capacity nearly 10 times. At the same time too
chemical reduction, sol gel deposition, thermal decomposition of much oxygen pressure results in loss of the mechanical stability
metal salts, etc. The sputtered catalysts are deposited as thin and therefore, an optimal set of sputter parameters has to be
compact catalytic films directly upon a selected substrate material, identified for best performance. In another study [13] we have
including on the gas diffusion electrode or even directly on the proven by XPS and SEM analysis that the type of plasma excitation
polymer electrolyte. The method is highly reproducible and (dc or rf) and the substrate temperature have little effect on the
enables both excellent homogeneous distribution of the metal deposited iridium oxide composition, but a remarkable effect on
particles on the substrate and extremely low, precisely controlled the film morphology.
In a recently published paper, Huang et al. [14] have
investigated thin Pt films deposited by rf sputtering. These films
have been used to fabricate MEAs for hydrogen/oxygen fuel cells.
* Corresponding author at: Institute of Electrochemistry and Energy Systems,
Bulgarian Academy of Sciences. G. Bonchev Street 10, 1113 Sofia, Bulgaria.
The authors have studied the influence of rf power and argon
Tel.: +359 2 971 1161; fax: +359 2 872 2544. partial pressure on the fuel cell performance. The results show that
E-mail address: slavcheva@ibas.bg (E. Slavcheva). in contrast to the argon pressure, which influences strongly the

0169-4332/$ – see front matter ß 2009 Elsevier B.V. All rights reserved.
doi:10.1016/j.apsusc.2009.02.033
6480 E. Slavcheva et al. / Applied Surface Science 255 (2009) 6479–6486

specific surface area and the electrochemical activity, the rf power The platinum films were deposited on glass substrates upon a
has much less effect on the properties of the sputtered Pt film. Wan very thin (25 nm) sputtered titanium adhesive layer. For each set
et al. [15] have studied the influence of low and high sputtering of sputtering parameters first the deposition rate was determined.
pressure (6  103 and 2  102 mTorr, respectively) on the Since the sputtering is a very stable and reproducible process, the
deposition rate, porosity, and surface area of thin Pt films and film thickness was controlled through variation of the sputtering
have found an improved surface morphology and shorter time. In order to obtain platinum films with optimal properties
deposition times at the higher pressure value. Another important regarding surface structure, morphology, roughness, porosity, and
parameter, influencing the rate of electrochemical reactions is the catalytic activity, the main sputtering parameters (argon pressure
thickness of the sputtered catalysts [1,16,17]. It affects the cost of and dc power) as well as the film thickness were systematically
catalysis (through the catalyst loading) and can have an essential varied. Three series of test samples were prepared. The samples
influence on the film structure and morphology. In such respect, from the first series were sputtered at constant argon pressure of
the film thickness is decisive for the catalytic efficiency, governing 68 mTorr, while varying the dc power in the range 50–1750 W. In
the overpotential and the rate controlling steps of the electrode the second series the catalysts were deposited at constant dc
reactions. The advantages of the sputtering method compared to power of 100 W, varying the argon pressure in the range 15–
the state of art chemical deposition techniques have been pointed 68 mTorr. The thickness of the test samples from the first two
out also by Alvisi et al. [18]. They have sputtered Pt on gas diffusion series was in the range 120–130 nm. Finally, a third series of test
electrodes for fuel cells and have shown that the sputtering samples was sputtered using constant power and argon pressure of
method enables strict control of the Pt cluster size. A very uniform 100 W and 68 mTorr, respectively, while varying the film thickness
particle distribution was observed resulting in an increased in the range 50–600 nm.
electrochemically active surface and decreased Pt loading relative
to a commercial chemically dispersed Pt catalyst. Cooper et al. have 2.2. Physical characterisation
published recently results on plasma sputtering of discrete
composition combinatorial libraries consisting of bi- and multi- The thickness of the sputtered platinum films was determined
component Pt alloys of the type PtMe. They have performed initial via a lift-off process using a Tencor P-10 surface-profilometer. The
screening of the catalytic efficiency of these libraries for ORR and surface structure and morphology were studied by methods of X-
have demonstrated the synergetic effect of the alloyed elements ray diffraction (XRD) and scanning electron microscopy (SEM). The
and the huge potential of the combinatorial approach for catalysts diffraction data were collected using an X-ray diffractometer
development and their initial characterisation [19,20]. The Philips PW 1830 at a constant rate of 0.01 2u s1 over an angle
influence of the sputtering parameters however, has not been range of 2u = 20–708 with a step size of 0.025 2u. The tube was set
presented in details. Thus, despite the increasing number of papers to an acceleration voltage of 40 kV at a current of 35 mA and a 0.2-
devoted to the electrocatalytic properties of thin metallic and/or 1-1 slit was used. The surface morphology was examined by a
metal oxide films and their various combinations deposited by ZEISS GEMINI 982 electron microscope with an acceleration
magnetron sputtering [1,5,9–11], this technique for catalysts voltage of 3 kV and a magnification up to 100 000. Sputtered
preparation is not thoroughly studied and its potential in the field samples were broken to obtain a cross section view.
of electrocatalysis is not acknowledged. The available data about
the influence of the sputtering parameters on the catalytic activity 2.3. Electrochemical characterisation
even of such a well-known and highly efficient catalyst as Pt are
still scare and somewhat ambiguous [21]. There is a clear need for The electrochemical characterisation was performed in 0.5 M
systematic research in order to enable fast and reliable selection of H2SO4 solution at temperature of 22 8C using the conventional
the sputtering process parameters depending on the desired electrochemical techniques of cyclic voltammetry and steady state
catalyst application. polarisation. The tests were carried out in a standard three
In the present research we have deposited a series of thin electrode glass cell with a high area Pt-wire counter electrode and
platinum films by dc magnetron sputtering varying systematically a silver–silver chloride reference electrode. The electrochemical
the process parameters and have investigated their influence on the measurements were performed with EG&G PAR 283 potentiostat
film structure and morphology in relation to the catalytic activity controlled by a PC and commercial software. The cyclic voltam-
toward the oxygen reduction (ORR) in acid aqueous solutions. The metry curves (CV) were recorded in argon purged electrolyte at a
performed parametric study focuses on the changes in film scan rate of 100 mV s1. The test electrodes with working area of
morphology including its depth profile at varying dc sputtering 0.5 cm2 exposed to the electrolyte were cycled between the onset
power, argon pressure, and film thickness, and the resulting effects potentials of hydrogen and oxygen evolution until a reproducible
on the electrochemical active surface area and catalytic efficiency. CV was obtained. The electrochemically active surface area, ECSA,
of Pt was determined from the charge in the hydrogen desorption
2. Experimental potential region QHdes using 210 mC cm2 as a conversion factor
according the procedure described in [21]. The quasi steady state
2.1. Deposition of the platinum films polarisation measurements were performed in O2 saturated
solutions at scan rate of 1 mV s1. The current density in the
Thin platinum films were prepared using a magnetron ORR peak of the CVs and the current density at 0.4 V from the
sputtering machine Nordiko 2550 which is a sputter down set cathodic polarisation curves were used to compare the activity of
up with up to three targets located over a rotating substrate table. different Pt films toward the oxygen reduction reaction. All
The platinum target used has a diameter of 600 (152.4 mm) and is potentials are given against the Ag/AgCl reference electrode (EAg/
bonded to a liquid cooled copper holder. The sputtering chamber AgCl = 0.2 V vs. NHE).
was evacuated to a base pressure of 3  103 mTorr, using rotary
vane and cryogenic pumps and then fed with argon gas at a 3. Results and discussion
constant flow rate of 100 sccm. The pressure was measured with a
MKS Baratron pressure gauge and controlled by a throttle, which To obtain a standardised film thickness at different sputtering
reduced the pumping speed of the cryogenic pump. The distance power the deposition rate had to be determined. The argon
between substrate and target was held at a constant 78 mm. pressure was held at a constant 68 mTorr and the working distance
E. Slavcheva et al. / Applied Surface Science 255 (2009) 6479–6486 6481

corner of each main SEM micrograph presenting the top view of the
sample, the corresponding cross sections, showing the depth
profile of selected sputtered Pt films are given. The SEM analysis
shows that all sputtered catalysts consist of homogenously
dispersed Pt particles which form a continuous compact film.
The samples deposited at lower dc powers consist of triangular
crystallites with dimensions of about 30–40 nm. The increase in
the plasma excitation gradually leads to a change in the shape
and formation of elongated surface structures. The films deposited
at a dc power of 1000 W and higher have a different surface
morphology with bigger cauliflower type structures. The depth
profile images show a columnar growth of the deposit and a trend
toward densification with the increasing power.
The XRD spectra in Fig. 5 show that the crystallinity increases
with the dc power. The reflection of [1 1 1] direction is pronounced,
Fig. 1. Deposition rate of platinum in relation to the sputtering power; the line is a while the [2 2 0] and [2 0 0] signals have much lower intensity. For
mathematical non-linear fit (the other sputtering parameters were held constant: reasons of clarity the inset of Fig. 5 shows only the [2 0 0] peak. No
argon pressure 68 mTorr).
distinct relationship between the sputtering power and this crystal
orientation is observed. There seems to be an initial growth in all
at 78 mm. Fig. 1 shows the obtained results. The different size of crystal orientations after which the [1 1 1] direction is predominant.
the error bars is a result of the assumed measuring error of the The observed effects are in accordance with the measured
Tencor Profilometer (10 nm) divided by the sputtering time. changes of the acceleration voltage. It was found that the increase
Different sputtering times were selected to achieve films with in the applied power from 50 to 1750 W resulted in a corres-
measurable thickness while reducing the amount of consumed ponding increase of the acceleration voltage (the voltage between
platinum. The measured results were fitted with a non-linear fitting the target and the common ground of the chamber) from 330 to
function y = a  Xb. One hundred iterations resulted in a of 0.1746 and 485 V. The registered voltage difference at a power increase from
b of 0.846. With this model we were able to predict the film thickness 100 to 1000 W was 90 V. The higher bias voltage results in higher
in an adequate accuracy. acceleration of the ionized argon toward the target leading to
sputtering of platinum particles with increased kinetic energy and
3.1. Surface analysis longer mean free path. This reduces the probability of collisions
with the Argon background gas. These Pt atoms or clusters hit
In order to follow the effect of the selected variable parameters the substrate surface with more energy and so have a higher
of the sputter process on the surface structure and morphology, all probability for hopping events, lattice rearrangements, and
samples were studied using SEM and XRD analysis. Selected SEM surface remodelling. Those effects in turn, cause the formation
images representing the influence of dc power, argon pressure, and of more tightly packed layers. This densification explains the non-
film thickness are shown in Figs. 2–4, respectively. The corre- linear growth of the deposition rate as well (Fig. 1). At higher
sponding XRD spectra are presented in Figs. 5–7. In the upper right sputtering power more platinum atoms are closely packed,

Fig. 2. SEM images of Pt films sputtered at varying dc power (argon pressure 68 mTorr; film thickness 125 nm).
6482 E. Slavcheva et al. / Applied Surface Science 255 (2009) 6479–6486

Fig. 3. SEM images of Pt films sputtered at varying argon pressure (dc power 100 W; film thickness 125 nm).

forming relatively thinner films. In addition, having a sufficient in the film thickness of about one order of magnitude. The SEM
energy the adatoms can be easily rearranged in the energetically images in Fig. 4 show a distinct crystal structure of all samples from
preferable [1 1 1] crystal orientation. this series. The size of the crystallites increases gradually with the
The influence of the argon pressure on the film structure and film thickness, following a clear epitaxial crystal growth in the
morphology is even more distinct but in the opposite direction [1 1 1] plane. These observations were confirmed unambiguously
(Fig. 3). The samples deposited at 15 mTorr are extremely smooth by the XRD spectra presented in Fig. 7. It can be seen that the signal
and featureless. The increase in argon pressure results in a more of the [1 1 1] direction increases in correspondence with the
columnar growth of the crystallites and larger voids in between. The thickness. There is no increase in the intensity of the [2 0 0]
depth profiles also demonstrate clear transformation to rougher and direction at all, while the [2 2 0] signal slightly decreases with
more porous films at higher argon pressure. The XRD (Fig. 6a) shows increasing thickness. These results prove that after an initial
again a preferred orientation in the [1 1 1] direction. The intensity of crystallisation in all directions the further Pt crystal growth is
the [1 1 1] peak reaches a maximum for the sample sputtered at predominately [1 1 1] oriented.
15 mTorr. The peak is extremely narrow indicating a highly oriented
nearly monocrystalline dense film, which is in accordance with 3.2. Electrochemical tests
the featureless SEM image of this sample. With the increase of the
sputtering pressure, the [1 1 1] reflection gradually decreases. The Fig. 8 presents the cyclic voltammetry curves of selected
other reflections seem to intensify and reach a maximum at samples deposited at systematic variation of the applied dc power
50 mTorr (inlay Fig. 6a). To illustrate the consistency of the observed (Fig. 8a) and the argon partial pressure (Fig. 8b) of the sputtering
changes in Fig. 6b are presented the diffraction peak spectra of the process. The shape of the CVs is nearly identical for all samples
full 2u range (20–908) normalized in respect to the intensity of the under study. The current response to the applied potential
[1 1 1] peak. There is a relative increase in the peak intensity of other scanning is typical for Pt in sulfuric acid solutions regarding both
crystal directions with the increasing pressure. The plausible the hydrogen and the oxygen potential regions. The current peaks
explanation for the established influence of pAr is that at lower corresponding to hydrogen adsorption/desorption phenomena are
pressures the sputtered particles have a longer mean free path situated in the potential range 0.3 to 0 V, the coverage of the
between the collisions with Ar atoms and radicals, resulting in a surface with oxygen containing species (Pt–O, Pt–OH) starts at
higher kinetic energy of the adatoms when they reach the substrate. about 0.7 V, the oxygen evolution reaction commences at
Similarly to the already discussed influence of the sputtering power, potentials above 1.2–1.3 V, while the current peak due to the
the particles having more energy, are more capable to hop and corresponding reduction of the adsorbed oxygen species (ORR
rearrange, thus forming a more compact metal film. Since the [1 1 1] peak) is well depicted at potentials of about 0.45–0.47 V (all
orientation is energetically more favourable, at low pressure the Pt potentials are vs. Ag/AgCl). On the other hand, distinct differences
crystals grow mainly in this direction [22,23]. are seen in the area under the voltammograms and the maximum
The samples from the third test series were sputtered at a fixed current density of the ORR peak. They increase essentially with the
power of 100 W and an argon pressure of 68 mTorr since the Pt decreasing power and the increase of the argon pressure. These
films deposited at these parameters have shown a surface opposite effects of the investigated sputter parameters are in
morphology considered as most favourable for the catalytic accordance with the differences in the morphology of the
properties. The sputter time was varied to ensure the variation deposited films established by SEM and XRD analysis (Figs. 2–7).
E. Slavcheva et al. / Applied Surface Science 255 (2009) 6479–6486 6483

Fig. 4. SEM images of sputtered Pt films with varying thickness (dc power 100 W; argon pressure 68 mTorr).

The observed changes in the surface structure and morphology densities in the maximum of the ORR peak are shown in Fig. 9a
of the sputtered Pt films lead to essential variations in the and b for the Pt films sputtered at varying plasma excitation and
electrochemically active surface area (ECSA). The values of the argon pressure, respectively. These parameters are characteristic
hydrogen desorption charge and the corresponding current for the accessible surface of the catalytic film and the activity
toward the process of oxygen reduction reaction, respectively. The
dependence of both QHdes and the jORR on the sputtering argon
pressure in the whole range of pAr studied is nearly linear. The ORR
current density decreases gradually with the increasing excitation
of the plasma. The calculated value of QHdes is maximal at 100 W,
while the further increase of the power causes a decrease of the
active surface of Pt. These results are in accordance with the
observed enlargement of the Pt crystallites and the densification of
the sputtered films with the increasing dc power, and the
deposition of rougher and more porous films with the increasing
argon pressure, proven by SEM data in Figs. 2 and 3. Taking into
account the experimental results obtained from the first and
second test series we have considered 100 W and 68 mTorr as
optimal sputter parameters regarding the electrochemical activity
and have used them to deposit a third test series of sputtered Pt
Fig. 5. XRD of Pt films sputtered at varying dc power (argon pressure 68 mTorr; film catalysts in order to study the influence of thickness on the
thickness 125 nm). The inlay shows a magnification of the [2 0 0] peak. catalytic efficiency and utilization of the Pt.
6484 E. Slavcheva et al. / Applied Surface Science 255 (2009) 6479–6486

Fig. 8. CV curves of 125 nm thick Pt films sputtered at (a) varying dc power,


pAr = 68 mTorr and (b) varying pAr, dc power of 100 W; recorded in 0.5 M H2SO4 at
22 8C and scan rate of 100 mV s1.

Fig. 6. XRD spectra of Pt films sputtered at varying argon pressure (dc power 100 W;
film thickness 125 nm); (a) peaks [1 1 1] and [2 0 0] and magnification of [2 0 0] as
inset; (b) 3D spectra normalized to the [1 1 1] peak.

The CV curves of the catalysts from the third series are


presented in Fig. 10a, while Fig. 10b shows the dependence of
the charge determined from the hydrogen desorption peak on
the film thickness. The ORR polarisation curves of these samples
are presented in Fig. 11. The values of ECSA and the
roughness factor, f, calculated from the hydrogen desorption
charge according to the procedure in [24] and the maximum
current densities in the ORR peak are summarized in Table 1.
In the same table are included data for jORR determined
from the polarisation measurements, which are indicative for

Fig. 7. XRD spectra of Pt films with varying thickness deposited at fixed sputter
parameters (dc power – 100 W; argon pressure – 68 mTorr. The inlay shows a Fig. 9. Hydrogen desorption charge and current density in the ORR peak determined
magnification of the [2 0 0] peak. from the CVs in Fig. 8 (a and b), respectively.
E. Slavcheva et al. / Applied Surface Science 255 (2009) 6479–6486 6485

Table 1
Characteristic electrochemical data of the Pt films with varying film thickness
sputtered at dc power of 100 W and argon pressure of 68 mTorr.

Thickness ECSA Roughness jpORR j0:4V


ORR
(nm) (cm2) factor*, f (mA cm2) (mA cm2)

50 8.02 15.94 1.69 0.036


125 18.47 36.72 4.15 0.165
275 24.07 47.85 10.12 0.246
375 37.75 75.05 12.06 0.292
600 47.09 93.62 18.38 0.298
*
f is obtained dividing the ECSA by the geometric area of the test electrode
(0.5 cm2).

Fig. 12. Normalized cathodic polarisation curves of the samples form Fig. 11.

Fig. 10. CV curves (a) and hydrogen desorption charge; (b) of Pt samples with
varying thickness sputtered at 100 W dc power and 68 mTorr argon pressure in
thickness, implies that there is no morphology change with the
0.5 M H2SO4 at 22 8C and scan rate of 100 mV s1. increasing thickness. On the other hand, the SEM images in Fig. 4
clearly show an enlargement of the Pt crystallites, e.g., a change in
the morphology. However, we have to remember that the ECSA is
the catalytic activity toward the partial reaction of oxygen determined from the CVs recorded in deaerated (Ar purged)
reduction. solutions using the area under the hydrogen desorption peaks,
As expected, the increase of the film thickness leads to an while the polarisation curves are recorded in oxygen saturated
increase in ECSA of the catalytic films and an improvement of the electrolytes, and that the protons, having higher mobility/lower
electrochemical activity toward both ORR and OER. This is due to size compared to the oxygen species most probably permeate
the increased number of active sites available for adsorption of the deeper in the porous Pt film thus, utilizing larger portions of the
reactants on the catalyst which intensifies the corresponding catalyst.
electrochemical reactions. At the same time the comparison of The results in Table 1 suggest also that the utilization of the Pt
polarisation curves shows that the current density does not catalyst is not linearly proportional to the ECAS and the catalytic
increase linearly with film thickness, suggesting that there is an loading. To illustrate this fact, in Fig. 12 are shown modified
optimal thickness above which the ORR is not facilitated cathodic polarisation curves for selected samples from the third
accordingly. These results at first glance seem contradictory. The test series where the measured current density is normalized to
fact that ECSA and the roughness factor scale linearly with the film the thickness of the Pt layer. As it is seen, although the increase of
film thickness above 300 nm still intensifies the rate of the ORR
slightly, the utilization of Pt catalyst decreases essentially and
therefore, the catalysis becomes more expensive. According to
these results the most reasonable and beneficial is to fix the Pt film
thickness in the range of 120–130 nm where the high catalytic
activity is combined with maximum utilization of the platinum. Of
course, the choice has to be made in relation to the envisaged
application of the sputtered platinum film and the current density
required for each specific case.

4. Conclusions

This paper presents a parametric study of dc magnetron


sputtered thin Pt films in which the influence of plasma excitation
dc power, inert gas pressure, and film thickness on the morphology
and catalytic activity toward ORR in sulfuric acid solutions was
Fig. 11. Cathodic polarisation curves of Pt films with varying thickness sputtered at
investigated. It was found that by varying the sputtering
100 W dc power and 68 mTorr argon Ar pressure recorded in 0.5 M H2SO4 at 22 8C at parameters it is possible to modify essentially the film morphology
1 mV s1. and thus, to tailor its electrochemical behaviour. High sputtering
6486 E. Slavcheva et al. / Applied Surface Science 255 (2009) 6479–6486

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