(001) silicon surfacial grain boundaries obtained by direct wafer bonding process: accurate control of the structure before bonding

Ultra-thin (001) silicon films bonded onto (001) silicon wafers, which form ‘surfacial grain boundaries’, are analysed by transmission electron microscopy and X-ray diffraction. The aim of this study is to find a way of controlling precisely, before direct wafer bonding, the structure of the Si/Si (001) interface. Two kinds of dislocation networks are found at the bonded interface. A square array of screw dislocations accommodates the twist between the two crystals, whereas a linear network of mixed dislocations accommodates the tilt resulting from the residual vicinality of the initial surfaces. A theoretical study shows that knowing and choosing before bonding the characteristics of these interfacial dislocations depend on the control of the ‘twist’ angle during the hydrophobic molecular bonding process. Recently, a new bonding method allows us to obtain an accuracy of ± 0.005° for the ‘twist’ angle from patterned grooves without any crystallographic measurement. The precision of this technique is compa...