The main limitation in the application of hydride vapor phase epitaxy for the large scale production of thick free-standing GaN substrates is the so-called parasitic deposition,
which limits the gro
wth time and
wafer thickness by blocking the gallium precursor inlet. By utilizing Cl
2 instead of the usual HCl gas for the production of the gallium chlorine precursor,
we found a rapid increase in gro
wth rate from 80 to 400 μm/h for an equally large flo
w of 25 sccm. This allo
wed us to gro
w,
without any additional optimization, 1.2 mm thick high quality GaN
wafers,
which spontaneously lifted off from their 0.3° mis-oriented GaN on sapphire HCl-based HVPE templates. These layers exhibited clear transparencies, indicating a high purity, dislocation densities in the order of 10
6 cm
−2, and narro
w rocking curve XRD FWHMs of 54 and 166 arcsec in for the 0002 and 101−5 directions, respectively.
In view of these findings, the possibility of depositing Cl2-based HVPE GaN directly on sapphire via the standard low temperature nucleation-high temperature overgrowth process of classic HCl-based HVPE was investigated. By varying the Cl2 flow during the 3 min long 615 °C nucleation phase, the nucleation conditions yielding smooth 0.7mm thick GaN on sapphire films were determined. The nucleation and coalescence mechanism of Cl2-based HVPE GaN was found to proceed similar to that of HCl-based HVPE.