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Chinese Physics B

Fabrication of Al/AlO x /Al junctions using pre-exposure technique at 30-keV e-beam voltage

Dong Lan, Guangming Xue, Qiang Liu, Xinsheng Tan, Haifeng Yu, Yang Yu

Published Jul 26, 2016• 2 citations
Publisher

Abstract

We fabricate high-quality Al/AlO x /Al junctions using improved bridge and bridge-free techniques at 30-keV e-beam voltage, in which the length of undercut and the size of junction can be well controlled by the pre-exposure technique. The dose window is 5 times as large as that used in the usual Dolan bridge technique, making this technique much more robust. Similar results, comparable with those achieved using a 100-keV e-beam writer, are obtained, which indicate that the 30-keV e-beam writer could be an economic choice for the superconducting qubit fabrication.

DOI
10.1088/1674-1056/25/8/088501

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We fabricate high-quality Al/AlO x /Al junctions using improved bridge and bridge-free techniques at 30-keV e-beam voltage, in which the length of undercut and the size of junction can be well controlled by the pre-exposure technique. The dose window is 5 times as large as that used in the usual Dolan bridge technique, making this technique much more robust. Similar results, comparable with those achieved using a 100-keV e-beam writer, are obtained, which indicate that the 30-keV e-beam writer could be an economic choice for the superconducting qubit fabrication.
We fabricate different-sized Al/AlO x /Al Josephson junctions by using a simple bridge-free technique, in which only single-layer E-beam resist polymethyl methacrylate (PMMA) is exposed at low accelerate voltage (below 30 kV) and the size of junction can be varied in a large range. Compared with the bridge technique, this fabrication process is very robust because it can avoid collapsing the bridge during fabrication. This makes the bridge-free technique more popular to meet different requirements for Josephson junction devices especially for superconducting quantum bits.
We present a novel shadow evaporation technique for the realization of junctions and capacitors. The design by e-beam lithography of strongly asymmetric undercuts on a bilayer resist enables in situ fabrication of junctions and capacitors without the use of the well-known suspended bridge (Dolan 1977 Appl. Phys. Lett. 31 337-9). The absence of bridges increases the mechanical robustness of the resist mask as well as the accessible range of the junction size, from 10(-2) µm(2) to more than 10(4) µm(2). We have fabricated Al/AlO(x)/Al Josephson junctions, phase qubit and capacitors using a 100 kV e-beam writer. Although this high voltage enables a precise control of the undercut, implementation using a conventional 20 kV e-beam is also discussed. The phase qubit coherence times, extracted from spectroscopy resonance width, Rabi and Ramsey oscillation decays and energy relaxation measurements, are longer than the ones obtained in our previous samples realized by standard techniques. These results demonstrate the high quality of the junction obtained by this bridge-free technique.
Nb/Al–AlO x /Nb tunnel junctions are often used in the studies of macroscopic quantum phenomena and superconducting qubit applications of the Josephson devices. In this work, we describe a convenient and reliable process using electron beam lithography for the fabrication of high-quality, submicron-sized Nb/Al–AlO x /Nb Josephson junctions. The technique follows the well-known selective Nb etching process and produces high-quality junctions with V m = 100 mV at 2.3 K for the typical critical current density of 2.2 kA/cm 2 , which can be adjusted by controlling the oxygen pressure and oxidation time during the formation of the tunnelling barrier. We present the results of the temperature dependence of the sub-gap current and in-plane magnetic-field dependence of the critical current, and compare them with the theoretical predictions.
The present thesis focuses on the laboratory fabrication of Al/AlOₓ/Al Josephson junctions using a bridge-free shadow evaporation technique, developed within the broader context of superconducting technologies for quantum computing. The interest in such devices arises from the central role played by the Josephson junction in superconducting qubits: unlike a purely harmonic LC oscillator, characterized by equally spaced energy levels, the presence of the junction introduces a nonlinearity that leads to an anharmonic energy spectrum. This allows for the selective addressing of the fundamental transition, which is a necessary condition for implementing a circuit-based qubit. In this framework, the quality of the AlOₓ tunnel barrier and of the metal interfaces is of crucial importance, as it directly affects not only the static electrical parameters of the junction but also dielectric losses and, more generally, the performance of the device in quantum applications. Following a theoretical overview of superconducting qubits and the physics of Al/AlOₓ/Al Josephson junctions, the work focuses on the experimental implementation and optimization of a bridge-free fabrication approach, adopted as an alternative to conventional suspended-bridge techniques. This method preserves the advantages of in-situ shadow evaporation for barrier formation while replacing the mechanical fragility of the suspended bridge with a geometrical control of the resist undercut. The operating principle relies on engineering an asymmetric profile in a bilayer resist system such that, during the two angled evaporations, only one deposition reaches the substrate along the connection lines, while the other is deposited on the resist sidewalls and subsequently removed during lift-off. In the central region, the overlap of the two evaporated aluminum layers, separated by an intermediate oxidation step, defines the Al/AlOₓ/Al superconductor–insulator–superconductor structure. This approach results in a more robust masking scheme compared to suspended-bridge processes, albeit at the cost of increased sensitivity to the precise definition and reproducibility of the undercut. The experimental activity was structured in several stages. First, the positive resists PMMA and MMA, used to form the bilayer lithographic stack, were characterized in order to determine their response as a function of electron-beam exposure dose and development conditions. A calibration mask consisting of an array of square patterns exposed at varying doses was employed to extract contrast curves and identify suitable exposure parameters. The development depth was quantitatively measured using atomic force microscopy (AFM), enabling a direct correlation between exposure dose and resulting resist profile. This step proved essential for selecting the most appropriate resist configuration capable of producing a controlled undercut compatible with the requirements of the bridge-free process. Subsequently, the lithographic process and evaporation geometry were calibrated through iterative refinement of the mask design, exposure parameters, and development conditions. Cross-sectional analysis, obtained via controlled sample cleaving followed by scanning electron microscopy (SEM), played a key role in assessing the three-dimensional profile of the resist, verifying the presence and quality of the undercut, and identifying potential structural instabilities such as resist collapse. At the same time, modifications were introduced to the evaporation system to enable deposition at the desired angles. This required the design of a new sample holder and a complete recalibration of the quartz crystal microbalance, as the altered geometry significantly affected the relationship between the nominal thickness reading and the actual film thickness deposited on the sample. A further important aspect of the work involved the progressive design and optimization of the full device mask, including contact pads, alignment markers, and the active junction region. The evolution of the layout, from initial test structures to the final configuration, was guided by experimental observations of pattern distortions and dose non-uniformities. It was found that the writing order of the electron-beam lithography pattern generator could significantly influence the final pattern quality, introducing systematic variations in feature definition. To mitigate this effect, a constrained writing sequence was implemented, ensuring improved reproducibility of the exposure process. Once all process parameters were stabilized, a comprehensive Standard Operating Procedure (SOP) was established, covering both the fabrication of Cr/Au contact structures and the subsequent lithography, angled evaporation, oxidation, and lift-off steps required for the realization of the Josephson junction. Finally, prior to fabricating fully oxidized junctions, a preliminary electrical validation of the process was carried out by producing test structures without the intermediate oxidation step. This allowed for the verification of electrical continuity in the aluminum structures. Measurements performed using a probe station confirmed ohmic behavior and the absence of macroscopic discontinuities in the conduction path. The measured resistance values were higher than those predicted using bulk aluminum resistivity; however, this discrepancy is consistent with the well-known behavior of thin evaporated films, in which surface scattering, grain boundaries, and interface effects lead to an increased effective resistivity. Although these measurements do not yet constitute a full characterization of the Josephson junction in the quantum regime, they provide an essential validation of the fabrication process and the structural integrity of the devices. In conclusion, this work enabled the development and calibration of a bridge-free fabrication process for Al/AlOₓ/Al Josephson junctions, highlighting the strong interplay between lithographic control, evaporation geometry, barrier formation, and electrical response. The main contribution of the thesis lies in transforming a conceptual fabrication approach into a structured and reproducible experimental procedure, based on resist characterization, cross-sectional analysis, instrumental recalibration, and preliminary electrical validation. The results obtained provide a solid foundation for further optimization of the tunnel barrier, cryogenic characterization, and integration of these junctions into superconducting circuits for quantum computing applications.
This paper explores methods to enhance the reproducibility of Josephson junctions, crucial elements in superconducting quantum technologies, when employing the Dolan technique in 30 kV e-beam processes. The study explores the influence of dose distribution along the bridge area on reproducibility, addressing challenges related to fabrication sensitivity. Experimental methods include E-beam lithography, with electron trajectory simulations shedding light on backscattered electron behavior. We demonstrate the fabrication of different junction geometries, revealing that some geometries significantly improve reproducibility by resulting in a more homogeneous dose distribution over the junction area.
Josephson junctions are the principal circuit element in numerous superconducting quantum information devices and can be readily integrated into large-scale electronics. However, device integration at the wafer scale necessarily depends on having a reliable, high-fidelity, and high-yield fabrication method for creating Josephson junctions. When creating Al/AlO x based superconducting qubits, the standard Josephson junction fabrication method relies on a sub-micron suspended resist bridge, known as a Dolan bridge, which tends to be particularly fragile and can often times fracture during the resist development process, ultimately resulting in device failure. In this work, we demonstrate a unique Josephson junction lithography mask design that incorporates stress-relief channels. Our simulation results show that the addition of stress-relief channels reduces the lateral stress in the Dolan bridge by more than 70% for all the bridge geometries investigated. In practice, our novel mask design significantly increased the survivability of the bridge during device processing, resulting in 100% yield for over 100 Josephson junctions fabricated.