Magnetoresistive sensor with enhanced uniaxial anisotropy

A method of forming a reader comprising:

• forming a bottom shield having a bottom surface, a top surface, a front surface and a back surface, wherein the front surface of the bottom shield forms a portion of a bearing surface of the reader;
• forming a recessed antiferromagnetic (AFM) layer on a rear portion of the top surface of the bottom shield, wherein the recessed AFM layer comprises a bottom surface, a top surface, a front surface and a back surface;
• forming a reader front shield on a front portion of the top surface of the bottom shield, wherein the reader front shield comprises a bottom surface, a top surface, a front surface and a back surface, wherein the back surface of the reader front shield is in contact with the front surface of the recessed AFM layer, and wherein the front surface of the reader front shield forms a portion of the bearing surface;
• forming a non-magnetic layer on the top surface of the reader front shield, wherein the non-magnetic layer comprises a bottom surface, a top surface, a front surface and a back surface, wherein the top surface of the non-magnetic layer is a corrugated surface, and wherein the front surface of the non-magnetic layer forms a portion of the bearing surface;
• and
• forming a pinned magnetic layer over the top surface of the recessed AFM layer and over the corrugated surface of the non-magnetic layer;
• forming a free layer over the pinned magnetic layer.

A method of forming a reader, the method comprising:

• forming a bottom shield;
• forming a non-magnetic layer over the bottom shield, the non-magnetic layer having a corrugated or rough upper surface;
• forming a first pinned layer on the corrugated or rough upper surface of the non-magnetic layer, wherein the first pinned layer comprises a bottom surface and a top surface, and wherein the bottom surface of the first pinned layer is in contact with the corrugated or rough upper surface, and wherein at least a portion of the top surface of the first pinned layer above the corrugated or rough upper surface is uneven;
• performing a smoothing operation on the top surface of the first pinned layer to remove the unevenness by:
• depositing a cap layer on the top surface of the first pinned layer;
• and
• applying plasma treatment to the cap layer and the first pinned layer to remove the cap layer and to partially remove the first pinned layer to provide a smooth top surface of the first pinned layer;
• and
• forming a free layer over the first pinned layer.