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This manuscript introduces and experimentally demonstrates a novel concept of selective metal ion irradiation by combining bipolar HIPIMS with conventional DC magnetron sputtering operation and simple DC biasing. The addition of the positive pulse to a conventional HIPIMS discharge accelerates the predominantly metal ions created during the negative HIPIMS phase with an energy proportional to the positive pulse amplitude and ionization state. Two distinct metal elements with large difference in atomic mass (Cr and Nb) are used on this work to irradiate a TiAlN matrix which is being deposited by conventional DCMS. The positive acceleration voltages used for both Cr and Nb discharges were varied between 0 to +200 V to analyze the influence of Nb and Cr metal ion irradiation on the mechanical and microstructural properties of TiAlN films. Even though the total metal ion incorporation into the TiAlN matrix for both Cr and Nb is less than 10% at%, strong effects are observed on the resulting film properties. It was observed that use of the lighter metal ion Cr is more beneficial than the heavier metal ion Nb. The Cr bombardment allows a hardness improvement from 7 to 22 GPa as well as a reduced film accumulated stress at the highest positive acceleration voltage. From the XRD measurements it is observed that the Cr atoms are inserted into the TiAlN cubic matrix maintaining its crystalline structure. However, the bombardment with the high-mass metal ion (Nb) promotes the deformation of the cubic TiAlN matrix, resulting in a spinodal decomposition and further degradation of the crystalline structure with the appearance of the hexagonal wurtzite-type Al-rich phase. This is also translated to the resulting film mechanical properties, as hardness rapidly decreases from 25 to 10 GPa and stress increases linearly with the positive voltage acceleration.

Selective Metal Ion Irradiation Using Bipolar HIPIMS: A New Route to Tailor Film Nanostructure and the Resulting Mechanical Properties