Thin film deposition from beams of atom clusters, some of which are io
nized and accelerated to the growing surface, was first proposed in 19
72. This idea created interest because it was fundamentally different
from other deposition methods and was expected to have unique capabili
ties. Development of a suitable cluster source has been difficult, and
large clusters of zinc (about 2000 atoms per cluster) have only recen
tly been produced. Two source parameters were changed to accomplish th
is. The crucible pressure was increased from 2 Torr to over 1000 Torr,
and a converging-diverging nozzle 18 mm long and 0.4 mm in diameter a
t the throat was used in place of the older nozzle with dimensions of
1 mm x 1 mm. To separate the pressure and nozzle effects, gold thin fi
lms are being deposited with the new converging-diverging nozzle. The
vapor pressure of gold is much lower than that of zinc at a given temp
erature. Cluster size measurements show no significant numbers of gold
clusters. The effect of the crucible pressure on the formation of the
large cluster is much more significant than that of the nozzle geomet
ry. The effects of varying ion energy bombardment on film microstructu
re are also evaluated using atomic force microscopy.