Lecture06-Thin Film Deposition
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EE143 – Fall 2016 Microfabrication Technologies Lecture 6: Thin Film Deposition Reading: Jaeger Chapter 6 Prof. Ming C. Wu [email protected] 511 Sutardja Dai Hall (SDH) 1 Vacuum Basics • Units – 1 atmosphere = 760 torr = 1.013x105 Pa – 1 bar = 105 Pa = 750 torr – 1 torr = 1 mm Hg – 1 mtorr = 1 micron Hg – 1 Pa = 7.5 mtorr = 1 newton/m2 – 1 torr = 133.3 Pa • Ideal Gas Law: PV = NkT – k = 1.38E-23 Joules/K = 1.37E-22 atm cm3/K – N = # of molecules (note the typo in your book) – T = absolute temperature in K 2 1 Dalton’s Law of Partial Pressure • For mixture of non-reactive gases in a common vessel, each gas exerts its pressure independent of others • ������ = �� + �� + ⋯ . +�� – Total pressure = Sum of partial pressures • ������ = �� + �� + ⋯ . +�� – Total number of molecules = sum of individual molecules • Ideal gas law observed by each gas, as well as all gases – ��� = ���� – ��� = ���� – ��� = ���� 3 Average Molecular Velocity • Assumes Maxwell- Boltzman Velocity Distribution 7 ��� �3 = �� • where m = molecular weight of gas molecule 4 2 Mean Free Path between collisions �� � = 7 ����� • where – K = Boltzmann constant – T = temperature in Kelvin – d = molecular diameter – P = pressure • For air at 300K �. � �. �� �(�� ��) = = � (�� ��) � (�� ����) 5 Impingement Rate • � = number of molecules striking a surface per unit area per unit time [1/cm2-sec] � � = �. �×���� 7 �� • where – P = pressure in torr – M = molecular weight 6 3 Question • How long does it take to form a monolayer of gas on the surface of a substrate? 7 Vacuum Basics (Cont.) At 25oC s) P 2 I 1 µm/min M Rate (Molecules/cm Residual Plasma Path (mm) Mean free Vacuum Processing Time to form a monolayer (sec) a monolayer form to Time CVD Impingment Pressure (Torr) 8 4 Thin Film Deposition Physical Methods Chemical Methods Evaporation Chemical Vapor Deposition (CVD) Sputtering Atomic Layer Deposition (ALD) Film substrate • Applications – Metalization (e.g., Al, TiN, W, Silicide) – Polysilicon – Dielectric layers (SiO2, Si3N4) 9 Evaporation wafer wafer deposited Al vapor deposited Al vapor Al film Al film e Al crucible is water cooled heating hot boat (e.g. W) electron source Thermal Evaporation Electron Beam Evaporation Gas Pressure: < 10-5 Torr 10 5 Evaporation: Filament & Electron Beam (a) Filament evaporation with loops of wire hanging from a heated filament (b) Electron beam is focused on metal charge by a magnetic field 11 Sputtering Negative Bias ( kV) I Al target + + Al Ar Ar Al Ar plasma Al Deposited Al film wafer heat substrate to ~ 300oC (optional) • Gas pressure ~ 1 to 10 mTorr • Deposition rate = constant × � × � – Where � = ion current – � = sputtering yield 12 6 Plasma Basics 13 Basic Properties of Plasma • The bulk of plasma contains equal concentrations of ions and electrons. • Electric potential is » constant inside bulk of plasma. The voltage drop is mostly across the sheath regions • Plasma used in IC processing is a “weak” plasma, containing mostly neutral atoms/molecules. – Degree of ionization is » 10-3 to 10-6 14 7 Outcomes of Plasma bombardment 15 Sputtering Yield Ar Al Al Al Sputtering Yield S # of ejected target atoms S º incoming ion. 0.1 < S < 30 16 8 Sputtering of Compound Targets AxBy Ar+ Aflux Bflux Target Because SA ¹ SB, target surface will acquire a composition Ax’By’ at steady state. 17 Reactive Sputtering Sputtering deposition Ti Target while introducing a reactive gas into the plasma. Example: N2 plasma • Formation of TiN + – Sputter a Ti target Ti, N2 with a nitrogen plasma TiN Substrate 18 9 Step Coverage Problem with PVD • Both evaporation and sputtering have directional fluxes Flux “geometrical film shadowing” step film wafer 19 Step Coverage concerns in contacts 20 10 Methods to Minimize Step Coverage Problems • Rotate + Tilt substrate during deposition • Elevate substrate temperature (why?) • Use large-area deposition source Sputtering Target 21 Advantages of Sputtering over Evaporation • For multi-component thin films, sputtering gives better composition control using compound targets. – Evaporation depends on vapor pressure of various vapor components and is difficult to control. • Better lateral thickness uniformity – Superposition of multiple point sources Sputtering Target Superposition of all small-area sources Profile due to one small-area source 22 11 Chemical Vapor Deposition (CVD) source chemical reaction film substrate More conformal deposition than PVD t Shown here is 100% conformal t deposition step 23 LPCVD Examples • SiO2 ���~���℃ ���� + �� ���� + ��� ↑ • PSG (phosphosilicate glass): doped glass – (~ �% ���� + ��% ����) – The film “reflows” at 900℃ ���~���℃ ���� + ��� ����� + ��� ↑ ���~���℃ ���� + �� ���� + ��� ↑ 24 12 LPCVD Examples • TEOS (Tetraethylorthosilicate) Si(OC2H5)4 ��(�����)�→ ���� + ������ ↑ – The liquid chemical TEOS is a safer alternative to gases silane or dichlorosilane Molecular structure of TEOS 25 LPCVD Examples • Si3N4 ����� + ���� → ����� + ���� ↑ • Polysilicon V°Y ���� �� + ��� ↑ • Tungsten ��� + ��� → � + ��� ↑ 26 13 CVD Mechanisms reactant 1 5 stagnant gas layer surface diffusion 2 3 4 Substrate 1 = Diffusion of reactant to surface 2 = Absorption of reactant to surface 3 = Chemical reaction 4 = Desorption of gas by-products 5 = Out-diffusion of by-product gas 27 CVD Deposition Rate [Grove Model] film � = � � � Si �� b F1 �� = ��� �� F3 d d = thickness of stagnant layer � − � � = � � � � � �� = ���� At steady state, �� = �� 28 14 Grove model of CVD (cont’d) � − � � = � � � = � � − � = � � = � � � � � � � � � �� �� = �� �� + �� � � � � = � � � = � � � � � � �� + �� + �� �� Film growth rate is constant with time: �� � = � �� � where � = atomic density of deposited film Note: This result is exactly the same as the Deal-Grove model for thermal oxidation with oxide thickness = 0 29 Deposition Rate vs. Temperature � gas transport limited � ∝ � � surface-reaction limited [log scale] [log Deposition Rate Deposition 0 1 / T high T low T 30 15 Growth Rate Dependence on Flow Velocity 31 CVD Features 1. More conformal deposition if T is uniform Wafer topography 2. Inter-wafer and intra-wafer thickness uniformity less sensitive to gas flow patterns. (i.e. wafer placement). 32 16 Comments about CVD (1) Sensitivity to gas flow pattern Furnace tube in wafers (2) Mass depletion problem in more less out 33 Plasma Enhanced CVD (PECVD) • Ionized chemical species allows a lower process temperature to be used – Plasma helps dissociate the precursor molecules at lower temperatures). • Film properties (e.g. mechanical stress) can be tailored by controlling ion bombardment with substrate bias voltage. 34 17 Atomic Layer Deposition (ALD) • The process involves two self-limiting half reactions that are repeated in cycles • Unlike CVD, in ALD pulses of precursors are introduced in each cycle • ALD is highly conformal and enables excellent thickness uniformity and control down to nm-scale 35 ALD for High-k Gate Dielectric 36 18.