Narrow Results

We report the experimental observations of large spatially disk-shaped patterns in an iron (Fe) film system deposited on silicone oil surfaces by a DC-magnetron sputtering method. These disk patterns form spontaneously during deposition and grow successively in vacuum condition after deposition. Their nucleation, growth and evolution are strongly dependent on the sputtering power, deposition period and growth time. The experiment indicates that they may result from the spontaneous organization and gathering of the Fe atoms and atomic clusters driven by the internal stress.

Various metal film systems, deposited on liquid (silicone oil) substrates by thermal evaporating and DC-magnetron sputtering methods, have been successfully fabricated and the stress relief mechanisms are systematically studied by analyzing the characteristic surface morphologies. The experiment shows that the evaporating metal films can move on silicone oil surfaces freely due to the nearly zero adhesion of solid–liquid interface, which results in spontaneous formation of ordered surface patterns with a characteristic sandwiched structure driven by the internal stress. For the sputtering metal film system, however, the top surface of silicone oil can be modified to form an elastomeric polymer layer on the liquid substrate during deposition. Subsequent cooling of the system creates a higher compressive stress in the film, which is relieved by buckling of the film to form periodic wavy structures because the adhesion of solid–elastomer interface is quite strong.

The growth mechanism and characteristic ordered patterns of iron (Fe) films deposited on the silicone oil surfaces by a DC-magnetron sputtering method are presented in this paper. It is found that as the film thickness increases, the iron atoms deposited on the oil surface first form compact clusters, then transfer to ramified aggregates and web-shaped structures, and finally form a continuous iron film. The average branch width of the ramified aggregates is about 0.34 μm, which is almost independent of the sputtering power, i.e., the deposition rate. In the continuous iron films, large spatially disk-shaped patterns are observed, which result from spontaneous ordered organization of the iron atoms and atomic clusters driven by the internal stress in this nearly free sustained film system.

The formation mechanism and surface evolution of thin silver films deposited on silicone oil substrates by a DC-magnetron sputtering method are reported. As the film thickness increases, the deposited silver atoms first form compact clusters, then transfer to ramified aggregates and finally form a continuous film on the liquid substrate. After deposition, the surface morphology of the silver film is susceptible to evolve successively in the atmosphere condition, resulting in the formation of broad cracks and straight-sided (or worm-like) wrinkles. The evolution behaviors and underlying physical mechanisms of the cracks and wrinkles are presented and discussed in detail.

In this paper, an optical microscopy study of orderly structures, namely bands, which are observed in a nearly free sustained copper (Cu) film system, is presented. The band is composed of a large number of parallel key-formed domains with different width w but nearly uniform length L. This study shows that the morphologies of the Cu films are very susceptible to the deposition rate, i.e. with the increase in the deposition rate f, the bands with rectangular domains first become irregular gradually and then disappear completely. The experiment indicates that the growth mechanism of the orderly patterns can be explained in terms of the relaxation of the internal stress in the films, which is related to the characteristic boundary condition of the films on the liquid substrates and the nearly zero adhesion of the solid–liquid interface.