The magnetic/mechanical spacing between the transducer and the disk significantly decreases due to thermal expansion of pole tips at stressed high temperature and high humidity tests. The protruded pole tips and alumina overcoat can cause head/disk contacts, resulting in thermal asperities and pole tip damage. The damage at the head–disk interface due to protruded pole tips and alumina overcoat may degrade the drive mechanical performance when flying height is below 10 nm. In this study the change in pole tin recession (PTR) with temperature and current in the writer coil, are measured using an optical profiler and an atomic force microscope for heads having a stack design with single and dual layers of writer coils. The pole tips protrude above the ABS surface by 3–4 nm when the temperature of the head is raised by 50°C. Heads with a single layer of writer coils exhibit significantly lower thermal PTR than those with dual layers of coils. The ABS profiles at elevated temperature generated using the finite element modeling of the differential thermal expansion of various layers in the head stack are in close agreement with the measured profiles. The thermal PTR and alumina overcoat protrusion can be reduced by optimizing the thermal expansion coefficient of the alumina basecoat and overcoat, the height of the head stack, and by replacing alumina by $SiO2$ and SiC.

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