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US 2017/0291856 A1Published application
Solution precursor plasma spray of ceramic coating for semiconductor chamber applications
AssigneeApplied Materials, Inc.
InventorsJennifer Y. Sun, Yikai Chen, Chengtsin Lee
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Abstract
Disclosed herein are methods for producing an ultra-dense and ultra-smooth ceramic coating. A method includes feeding a solution comprising a metal precursor into a plasma sprayer. The plasma sprayer generates a stream toward an article, forming a ceramic coating on the article upon contact.
Claims20
A method comprising:
- providing an article;
- feeding a solution into a plasma sprayer, wherein the solution comprises a metal precursor;
- and
- generating, with the plasma sprayer, a stream directed toward the article, wherein the stream forms a ceramic coating on the article upon contact with the article, and wherein the ceramic coating comprises:
- 50-75 mol % of Y2O3, 10-30 mol % of ZrO2, and 10-30 mol % of Al2O3;
- 40-100 mol % of Y2O3, 0-60 mol % of ZrO2, and 0-10 mol % of Al2O3;
- 60-75 mol % of Y2O3, 20-30 mol % of ZrO2, and 0-5 mol % of Al2O3;
- 60-70 mol % of Y2O3, 30-40 mol % of ZrO2, and 0-10 mol % of Al2O3;
- 50-60 mol % of Y2O3 and 40-50 mol % of ZrO2;
- 40-60 mol % of Y2O3, 30-50 mol % of ZrO2, and 10-20 mol % of Al2O3;
- 40-50 mol % of Y2O3, 20-40 mol % of ZrO2, and 20-40 mol % of Al2O3;
- 70-90 mol % of Y2O3, 0-20 mol % of ZrO2, and 10-20 mol % of Al2O3;
- 60-80 mol % of Y2O3, 0-10 mol % of ZrO2, and 20-40 mol % of Al2O3;
- 40-60 mol % of Y2O3, 0-20 mol % of ZrO2, and 30-40 mol % of Al2O3;
- 30-60 mol % of Y2O3, 0-20 mol % of ZrO2, and 30-60 mol % of Al2O3;
- 20-40 mol % of Y2O3, 20-80 mol % of ZrO2, and 0-60 mol % of Al2O3;
- or
- 1-99 mol % Y2O3 and 1-99 mol % YF3.
15 more elements
A method comprising:
- providing an article, the article comprising a first ceramic coating disposed thereon;
- feeding solution into a plasma sprayer, the solution comprising a metal precursor;
- and
- plasma spraying the solution onto the first ceramic coating to form a second ceramic coating, wherein at least one of the first or second ceramic coatings comprises a ceramic compound comprising Y4Al2O9 and a solid-solution of Y2O3—ZrO2.
1 more element
(canceled)
Dependencies are inferred from the claim text.