Inverted merged MR head with precise track width

摘要

A method makes an inverted merged MR head with a second pole tip layer which is self-aligned with a top first pole tip layer. After forming a bottom first pole tip layer, which is relatively thin and relatively wide, a top first pole tip layer is formed thereon with a width that defines the track width of the merged MR head. A second pole tip forming layer is formed on the top first pole tip layer and layers adjacent both sides of the top first pole tip layer. The forming layer and the top first pole tip layer are lapped so that their top surfaces are flush with one another. Ion milling is then implemented to mill the top first pole tip layer at a faster rate than the forming layer causing a recess that is defined by a top surface of the top first pole tip layer and inclined surfaces of the forming layer immediately adjacent thereto. After formation of a write gap layer in the recess a second pole tip layer is formed in a recess replicated by the write gap layer causing a bottom base portion of the second pole tip layer to be substantially the same width as the track width and aligned with the top first pole tip layer so that flux can be transferred between the pole tips more narrowly confined within the track width.