Ordered Nano-Crystal Arrays Spontaneously Form in Films Evaporated onto Nanopore Array Substrates

We present SEM images of films thermally evaporated onto Anodic Aluminum Oxide substrates that are patterned with a hexagonal array of 34 and 80 nm diameter holes spaced by 100 nm. Over a range of film thicknesses, Pb and Sn films spontaneously self assemble into an array of nano-crystals in registry with the underlying hole lattice. The development of the arrays with thickness indicates that surface energies drive coalescing grains to move over the holes. Materials that wet the substrate or whose grains do not coalesce at these substrate temperatures do not form arrays. We discuss some potential applications.