By combining a hollow-cathode plasma sputter device with the gas aggre
gation technique, an intense source of nanoscale metal clusters has be
en developed. Net sputtering rates have been measured as a function of
pressure, flow velocity, electric current and cathode geometry, and i
n most instances they were found to behave differently than their plan
ar-electrode sputtering counterparts. Deposition rates on substrates l
ocated away from the hot plasma region have been also measured. Cluste
rs of Cu, Ag, Au and Ta have been produced and their size has been det
ermined via XRD and TEM. The size of Cu-n clusters is found to in crea
se with the sputter source discharge current.