Atomic layer deposition (ALD) is comprised of sequential self-limiting surface reactions that are inherently sensitive to the surface chemistry of the substrate and the reactivity of the chosen precursors. In order to better understand ALD processes and direct their future development we must investigate the fundamental mechanisms of ALD reactions. This is commonly done using a combination of computational modeling and experimental investigations using techniques like spectroscopic ellipsometry and IR spectroscopy. We present pyroelectric calorimetry for ALD as an in situ technique to measure the time resolved heat generation from ALD reactions. This provides a new dimension of thermodynamic and kinetic reaction data.

As an experimental technique, pyroelectric calorimetry measures ALD reactions on realistic surfaces as opposed to idealized models. We have designed and constructed custom calorimeters that are compatible with typical ALD process parameters. These calorimeters have been calibrated with a thermal resolution down to 0.1 μJ/cm² and a temporal resolution of 50ns. To put this in perspective for an ALD reaction, this corresponds to about 0.1% of the heat evolved in the trimethylaluminum (TMA) and water ALD process and about 10⁴ faster than our measurement of the TMA half reaction. The temporal resolution of our calorimeters is orders of magnitude faster than most complementary in situ analysis techniques including ellipsometry, IR spectroscopy, quartz crystal microgravimetry, and mass spectrometry. This time resolution provides information on precursor flow dynamics and reaction kinetics.

Pyroelectric calorimetry was used to investigate the TMA and water half reactions for ALD Al₂O₃ along with in situ spectroscopic ellipsometry thickness measurements and Rutherford backscattering spectrometry (RBS) composition analysis. This enabled comparisons of the change in thickness with the amount of heat generated as each half reaction saturates. Atomic growth rates calculated form RBS were used to calculate the heat generated on a per-atom basis. These results were then compared with proposed reaction mechanisms and energy changes from density functional theory (DFT) computational modeling.

Measurements of reaction and adsorption heats can also be used to compare and evaluate different precursors and inhibitor molecules for ALD growth inhibition in area-selective ALD. We investigated how the thermodynamics of adsorption can guide our choice of precursor-inhibitor pairs when using small molecule inhibitors that rely on competitive adsorption and chemical passivation to prevent ALD growth. Pyroelectric calorimetry offers new insight into what drives and limits ALD reactions and provides many opportunities for future investigations.