Surface Optimization of Superconducting Aluminum Resonators for Robust Quantum Device Fabrication

Aluminum (Al) remains the central material for superconducting qubits, and considerable effort has been devoted to optimizing its deposition and patterning for quantum devices. However, post-processing strategies focused on oxide removal of niobium (Nb) and tantalum (Ta) -based resonators using buffered oxide etch (BOE), which can not be used for Al. This challenge becomes particularly relevant for industry-scale fabrication with multi-chip bonding, where delays between sample preparation and cooldown require surface treatments that preserve low dielectric loss during extended exposure to ambient conditions. In this work, we investigate surface modification approaches for Al resonators subjected to a 24-hour delay prior to cryogenic measurement. Passivation using self-limiting oxygen and fluorine chemistries was evaluated utilizing different plasma processes. Remote oxygen plasma treatment reduced dielectric losses, in contrast to direct oxygen plasma. A fluorine-based plasma process was developed that passivated the Al surface for subsequent BOE treatment. However, the fluorine content in the surface resulted in higher loss, identifying fluorine as an unsuitable passivation material for Al resonators. Above all, selective oxide removal using HF (hydrogen fluoride) vapor and phosphoric acid yielded median dielectric losses as low as $\tildeδ_\mathrm{LP} = 5.7 \times 10^{-7}$ ($Q_\mathrm{LP} \approx 1.7\,\mathrm{M}$) with $\tildeδ_\mathrm{TLS} = 3.6 \times 10^{-7}$ ($Q_\mathrm{TLS} \approx 2.8\,\mathrm{M}$) in the single photon regime. Selective oxide removal provides a promising pathway for robust Al-based qubit fabrication, as it preserves low dielectric losses for a 24-hour delay before cooldown.