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Development of a Deep-Submicron CMOS Process for Fabrication of High Performance 0.25 m Transistors Michael Aquilino Microelectronic Engineering Department Rochester Institute of Technology April 21, 2005 Motivation Enable the Microelectronic Engineering department to continue the semiconductor industry trend of fabricating high performance transistors that have faster switching speeds, increased density and functionality, and ultimately a decrease in cost per function. Push the limits of the SMFL in all areas from design to fabrication to test Create a baseline process that can be used to integrate strained silicon, metal gates, high-k gate dielectrics, and replacement gate technologies at RIT Rochester Institute of Technology Microelectronic Engineering 2 Outline RIT/Industry Scaling Trends Gate Control Fundamentals Short Channel Effects Deep-Submicron Scaling Unit Process Development Layout Integration/Fabrication/Test Time Line Questions Rochester Institute of Technology Microelectronic Engineering 3 RIT/Industry Scaling Trends Table 1: RIT/Industry Scaling Trends [3] Gate Length Frequency Transistors Supply Voltage Date Processor Family (μm) (V) November 1971 4004 10 108 KHz 2,300 15 April 1974 8080 6 2 MHz 6,500 12 June 1978 8086 3 10 MHz 29,000 5 February 1982 Intel 80286 1.5 12 MHz 134,000 5 March 1995 Intel Pentium 0.6 120 MHz 3,300,000 3.5 **May 2004 RIT Submicron NMOS 0.5 3.5 August 1999 Intel Pentium 2 & 3 0.25 600 MHz 9,500,000 2.0 **September 2005 RIT Deep-Submicron CMOS 0.25 2.0 September 2001 Intel Pentium 3 & 4 0.18 2.0 GHz 45,000,000 1.7 February 2004 Intel Pentium 4 0.13 3.4 GHz 55,000,000 1.5 June 2004 Intel Pentium 4 0.09 3.6 GHz 125,000,000 1.4 o Over last 30 years, transistors have gotten smaller and faster o 110x reduction in gate length o 36,000x increase in switching speed o Integrated circuits have become much more complex o 54,000x increase in number of transistors on an IC Rochester Institute of Technology Microelectronic Engineering 4 RIT/Industry Scaling Trends Table 1: RIT/Industry Scaling Trends [3] Gate Length Frequency Transistors Supply Voltage Date Processor Family (μm) (V) November 1971 4004 10 108 KHz 2,300 15 April 1974 8080 6 2 MHz 6,500 12 June 1978 8086 3 10 MHz 29,000 5 February 1982 Intel 80286 1.5 12 MHz 134,000 5 March 1995 Intel Pentium 0.6 120 MHz 3,300,000 3.5 **May 2004 RIT Submicron NMOS 0.5 3.5 August 1999 Intel Pentium 2 & 3 0.25 600 MHz 9,500,000 2.0 **September 2005 RIT Deep-Submicron CMOS 0.25 2.0 September 2001 Intel Pentium 3 & 4 0.18 2.0 GHz 45,000,000 1.7 February 2004 Intel Pentium 4 0.13 3.4 GHz 55,000,000 1.5 June 2004 Intel Pentium 4 0.09 3.6 GHz 125,000,000 1.4 o In May of 2004 an NMOS transistor with LPOLY = 0.5 µm was developed o This is RIT’s smallest transistor with LEFFECTIVE = 0.4 µm o This is the same technology as the Intel Pentium from 9 years earlier Rochester Institute of Technology Microelectronic Engineering 5 RIT/Industry Scaling Trends Table 1: RIT/Industry Scaling Trends [3] Gate Length Frequency Transistors Supply Voltage Date Processor Family (μm) (V) November 1971 4004 10 108 KHz 2,300 15 April 1974 8080 6 2 MHz 6,500 12 June 1978 8086 3 10 MHz 29,000 5 February 1982 Intel 80286 1.5 12 MHz 134,000 5 March 1995 Intel Pentium 0.6 120 MHz 3,300,000 3.5 **May 2004 RIT Submicron NMOS 0.5 3.5 August 1999 Intel Pentium 2 & 3 0.25 600 MHz 9,500,000 2.0 **September 2005 RIT Deep-Submicron CMOS 0.25 2.0 September 2001 Intel Pentium 3 & 4 0.18 2.0 GHz 45,000,000 1.7 February 2004 Intel Pentium 4 0.13 3.4 GHz 55,000,000 1.5 June 2004 Intel Pentium 4 0.09 3.6 GHz 125,000,000 1.4 o By September of 2005, this process will yield CMOS transistors with LPOLY = 0.25 µm and LEFFECTIVE = 0.18 µm o This technology was used in high volume manufacturing of the Intel Pentium III at 600 MHz only 6 years ago o The gap between industry and RIT is rapidly shrinking Rochester Institute of Technology Microelectronic Engineering 6 Outline RIT/Industry Scaling Trends Gate Control Fundamentals Short Channel Effects Deep-Submicron Scaling Unit Process Development Layout Integration/Fabrication/Test Time Line Questions Rochester Institute of Technology Microelectronic Engineering 7 Gate Control Fundamentals o NMOS Transistor o 4 Terminal Device o Gate o Source o Drain o Body Figure 1: Schematic of NMOS Transistor [4] To turn transistor on: o Apply positive charge to Gate, QG o A depletion region in the p-type body is created as positively charged holes are repelled by gate, exposing negatively charged acceptor ions, QB o As the gate charge is further increased, electrons from the source diffuse into the channel and become inversion charge, QI o QG = QB + QI Rochester Institute of Technology Microelectronic Engineering 8 Gate Control Fundamentals o The source and body terminals are grounded o A positive voltage is applied to the drain, VDS o Inversion charge moves from source to drain and is the current in the device o Figure 1: Schematic of NMOS Transistor [4] Equation 1 shows the classical derivation for drain current in a transistor by integrating the inversion charge along the channel W ID L Rochester Institute of Technology Microelectronic Engineering VD VS nQn(V )dV (Eq. 1) 9 Gate Control Fundamentals o A depletion region from the drain is created by the reverse biased body-drain p-n+ diode o The positively charged donor ions in drain support some of the negative inversion charge Figure 1: Schematic of NMOS Transistor [4] o This is known as “Charge Sharing” as the gate does not have full control over the inversion channel o For large gate lengths, the contribution of the drain in controlling the inversion layer is small compared to the gate contribution o As transistors are scaled smaller in gate length, the drain has a larger percentage contribution in supporting inversion charge in the channel Rochester Institute of Technology Microelectronic Engineering 10 Outline RIT/Industry Scaling Trends Gate Control Fundamentals Short Channel Effects Deep-Submicron Scaling Unit Process Development Layout Integration/Fabrication/Test Time Line Questions Rochester Institute of Technology Microelectronic Engineering 11 Short Channel Effects o “Gate Control” is the most important concept in scaling of transistors o The consequence of the drain taking control away from the gate is short channel effects such as: o VT Roll-off o Drain Induced Barrier Lowering (DIBL) o Punch-through Threshold Voltage (volts) Vt Rolloff vs. Leff o Threshold voltage decreases as gate length decreases o For small enough gate lengths the devices will be on at 0 V 1 0.8 0.6 0.4 0.2 0 0.4 0.5 0.6 0.7 0.8 0.9 1 Leff (um ) Figure 2 : VT Roll-off Effect [1] Rochester Institute of Technology Microelectronic Engineering 12 Short Channel Effects o “Gate Control” is the most important concept in scaling of transistors o The consequence of the drain taking control away from the gate is short channel effects such as: o VT Roll-off o Drain Induced Barrier Lowering (DIBL) o Punch-through o Increased off-state leakage with increase in drain voltage o If gate were in full control, these curves would be one on top of the other Figure 3: Drain Induced Barrier Lowering (DIBL) [1] Rochester Institute of Technology Microelectronic Engineering 13 Short Channel Effects o “Gate Control” is the most important concept in scaling of transistors o The consequence of the drain taking control away from the gate is short channel effects such as: o VT Roll-off o Drain Induced Barrier Lowering (DIBL) o Punch-through o At high drain bias, the drain takes control of current through the device o Excessive heating can occur and cause device failure Figure 4: Lateral source/drain Punch-through [4] Rochester Institute of Technology Microelectronic Engineering 14 Short Channel Effects o “Gate Control” is the most important concept in scaling of transistors o The consequence of the drain taking control away from the gate is short channel effects (SCE) such as: o VT Roll-off o Drain Induced Barrier Lowering (DIBL) o Punch-through o Transistors with short channel effects are undesirable o These SCE must be minimized to yield long-channel transistors Rochester Institute of Technology Microelectronic Engineering 15 Outline RIT/Industry Scaling Trends Gate Control Fundamentals Short Channel Effects Deep-Submicron Scaling Unit Process Development Layout Integration/Fabrication/Test Time Line Questions Rochester Institute of Technology Microelectronic Engineering 16 Deep-Submicron Scaling The goal in deep-submicron scaling is to maximize the gate control for switching the device on and off by scaling physical and electrical parameters o Table 2: 0.25 µm Scaling Parameters from NTRS Roadmap [6] ION 600 A/μm IOFF 1 nA/μm Log(ION / IOFF) 5.75 decades SS 85 mV/decade DIBL < 100 mV/V VDD 1.8 – 2.5 V | VT | 0.5 V Tox 40 - 50 Å XJ (shallow LDD) 50 – 100 nm ND (LDD) 2 - 5 x1018 cm-3 RS (LDD) 400 – 850 sq XJ (contact) 135 – 265 nm ND (contact) 1x1020 cm-3 XJ (SSRW channel) 50 – 100 nm Figure 5: Physical Scaling Guidelines [7] Rochester Institute of Technology Microelectronic Engineering 17 Deep-Submicron Scaling The goal in deep-submicron scaling is to maximize the gate control for switching the device on and off by scaling physical and electrical parameters o Table 2: 0.25 µm Scaling Parameters from NTRS Roadmap [6] ION 600 A/μm IOFF 1 nA/μm Log(ION / IOFF) 5.75 decades SS 85 mV/decade DIBL < 100 mV/V VDD 1.8 – 2.5 V | VT | 0.5 V o o o o o Tox 40 - 50 Å XJ (shallow LDD) 50 – 100 nm ND (LDD) 2 - 5 x1018 cm-3 RS (LDD) 400 – 850 sq XJ (contact) 135 – 265 nm ND (contact) 1x1020 cm-3 XJ (SSRW channel) 50 – 100 nm Decrease gate oxide thickness Gate is closer to the channel More control in switching device off Cox since Cox = A/tox or Cox =Q/V ID and gm since Cox Figure 5: Physical Scaling Guidelines [7] Rochester Institute of Technology Microelectronic Engineering 18 Deep-Submicron Scaling The goal in deep-submicron scaling is to maximize the gate control for switching the device on and off by scaling physical and electrical parameters o Table 2: 0.25 µm Scaling Parameters from NTRS Roadmap [6] ION 600 A/μm IOFF 1 nA/μm Log(ION / IOFF) 5.75 decades SS 85 mV/decade DIBL < 100 mV/V VDD 1.8 – 2.5 V | VT | 0.5 V Tox 40 - 50 Å XJ (shallow LDD) 50 – 100 nm ND (LDD) 2 - 5 x1018 cm-3 RS (LDD) 400 – 850 sq XJ (contact) 135 – 265 nm ND (contact) 1x1020 cm-3 XJ (SSRW channel) 50 – 100 nm Decrease junction depth of source/drain o Depletion region from gate dominates depletion region from the drain o Trade-off is sheet resistance and ID o ND must which will cause RS o Figure 5: Physical Scaling Guidelines [7] Rochester Institute of Technology Microelectronic Engineering 19 Deep-Submicron Scaling The goal in deep-submicron scaling is to maximize the gate control for switching the device on and off by scaling physical and electrical parameters o Table 2: 0.25 µm Scaling Parameters from NTRS Roadmap [6] ION 600 A/μm IOFF 1 nA/μm Log(ION / IOFF) 5.75 decades SS 85 mV/decade DIBL < 100 mV/V VDD 1.8 – 2.5 V | VT | 0.5 V Tox 40 - 50 Å XJ (shallow LDD) 50 – 100 nm ND (LDD) 2 - 5 x1018 cm-3 RS (LDD) 400 – 850 sq XJ (contact) 135 – 265 nm ND (contact) 1x1020 cm-3 XJ (SSRW channel) 50 – 100 nm Use sidewall spacer to create deeper source/drain junction called the contact o Typically ~2x as deep as shallow LDD o Doped heavily to reduce RS o Figure 5: Physical Scaling Guidelines [7] Rochester Institute of Technology Microelectronic Engineering 20 Deep-Submicron Scaling The goal in deep-submicron scaling is to maximize the gate control for switching the device on and off by scaling physical and electrical parameters o Table 2: 0.25 µm Scaling Parameters from NTRS Roadmap [6] ION 600 A/μm IOFF 1 nA/μm Log(ION / IOFF) 5.75 decades SS 85 mV/decade DIBL < 100 mV/V VDD 1.8 – 2.5 V | VT | 0.5 V Tox 40 - 50 Å XJ (shallow LDD) 50 – 100 nm ND (LDD) 2 - 5 x1018 cm-3 RS (LDD) 400 – 850 sq XJ (contact) 135 – 265 nm ND (contact) 1x1020 cm-3 XJ (SSRW channel) 50 – 100 nm Increase doping of channel to decrease the depletion region from the source/drain o Use a retrograde profile where doping is low at the surface and higher sub-surface o Mobility of carriers o ID and gm since both are mobility o Rochester Institute of Technology Microelectronic Engineering Figure 5: Physical Scaling Guidelines [7] 21 Deep-Submicron Scaling The goal in deep-submicron scaling is to maximize the gate control for switching the device on and off by scaling physical and electrical parameters o Table 2: 0.25 µm Scaling Parameters from NTRS Roadmap [6] ION 600 A/μm IOFF 1 nA/μm Log(ION / IOFF) 5.75 decades SS 85 mV/decade DIBL < 100 mV/V VDD 1.8 – 2.5 V | VT | 0.5 V Tox 40 - 50 Å XJ (shallow LDD) 50 – 100 nm ND (LDD) 2 - 5 x1018 cm-3 RS (LDD) 400 – 850 sq XJ (contact) 135 – 265 nm ND (contact) 1x1020 cm-3 XJ (SSRW channel) 50 – 100 nm o As TOX , gate leakage current o VDD must to reduce this leakage o VT must so (VGS-VT) , this is “Gate Overdrive” and is ID o Want ION since gate delay ION-1 Rochester Institute of Technology Microelectronic Engineering RC ION 22 Deep-Submicron Scaling The goal in deep-submicron scaling is to maximize the gate control for switching the device on and off by scaling physical and electrical parameters o Table 2: 0.25 µm Scaling Parameters from NTRS Roadmap [6] ION 600 A/μm IOFF 1 nA/μm Log(ION / IOFF) 5.75 decades SS 85 mV/decade DIBL < 100 mV/V VDD 1.8 – 2.5 V | VT | 0.5 V o o o o o Tox 40 - 50 Å XJ (shallow LDD) 50 – 100 nm ND (LDD) 2 - 5 x1018 cm-3 RS (LDD) 400 – 850 sq XJ (contact) 135 – 265 nm ND (contact) 1x1020 cm-3 XJ (SSRW channel) 50 – 100 nm Want IOFF to be low to reduce standby power The industry standard metric is 1 nA/µm of off-current This results in 5.75 decades between ION and IOFF There is 500 mV swing between 0 V and VT SS of 85 mV/decade is needed to turn the device off SS KT CD ln 10 1 q COX Rochester Institute of Technology Microelectronic Engineering Theoretical limit ~ 60 mV/decade @ 300K 23 Outline RIT/Industry Scaling Trends Gate Control Fundamentals Short Channel Effects Deep-Submicron Scaling Unit Process Development Layout Integration/Fabrication/Test Time Line Questions Rochester Institute of Technology Microelectronic Engineering 24 0.25 µm Device Technology o Unit Processes will be developed to yield cross-section shown in Figure 6 Aluminum Nitride Spacers P+ Poly N+ Poly P+ Well Contact STI N+ S/D LDD P+ S/D TiSi2 P-SSRW P-Well N+ Well Contact LDD N-SSRW N-Well N-Substrate Figure 6: CMOS Cross Section showing NMOS (left) and PMOS (right) Transistors • Shallow Trench Isolation Dual Doped Poly Gates 50 Å gate oxide w/ N2O Low Doped Source/Drain Extensions Titanium Silicide Rochester Institute of Technology Microelectronic Engineering • Super Steep Retrograde Twin Well Nitride Sidewall Spacers Rapid Thermal Dopant Activation 2 Level Aluminum Metallization Back End CMP 25 Unit Process Development Shallow Trench Isolation Channel Engineering Uniformly Doped Twin Well Super Steep Retrograde Well Ultra Thin Gate Oxide P-Well Gate Formation N-Substrate Lithography Figure 7: Resist Trimming Reactive Ion Etch (RIE) of Gate Source/Drain/Gate Doping Poly re-ox Low Doped Source/Drain Extensions Sidewall Spacers Source/Drain Contacts Dual Doped Poly Rapid Thermal Dopant Activation Titanium Salicide Contact Cut Etch 2 Level Aluminum Metallization Aluminum Nitride Spacers P+ Poly N+ Poly P+ Well Contact LDD P-SSRW Rochester Institute of Technology Microelectronic Engineering STI N+ S/D P+ S/D TiSi2 N+ Well Contact LDD N-SSRW N-Well Shallow Trench Isolation 26 Shallow Trench Isolation o Replacement of LOCOS as preferred isolation technology o LOCOS suffers from “Bird’s Beak” effect o Field oxide encroaches into active region, reducing W o Reduction in Width leads to reduction in drive current o To recover this loss, transistors must be made wider which takes up more real estate o Small geometries are not possible since Bird’s Beak oxide encroaches from both sides of active area o With STI, WACTUAL ≈ WDRAWN o Increased packing density o Higher drive current for devices with same WDRAWN o Decreased topography early in the process Rochester Institute of Technology Microelectronic Engineering 27 Shallow Trench Isolation o o o Grow Pad Oxide Deposit Nitride by LPCVD Pattern and Etch Silicon Trench Figure 8: STI Process after trench etch Grow liner oxide to repair silicon and round off sharp corners o Fill with PECVD TEOS Oxide o Figure 9: STI Process after trench fill o o o CMP trench oxide Use Nitride as etch stop Remove Nitride in H3PO4 acid Figure 10: STI Process after CMP Rochester Institute of Technology Microelectronic Engineering 28 Unit Process Development Shallow Trench Isolation Channel Engineering Uniformly Doped Twin Well Super Steep Retrograde Well Ultra Thin Gate Oxide Gate Formation Lithography Resist Trimming Reactive Ion Etch (RIE) of Gate Source/Drain/Gate Doping Poly re-ox Low Doped Source/Drain Extensions Sidewall Spacers Source/Drain Contacts Dual Doped Poly Rapid Thermal Dopant Activation Titanium Salicide Contact Cut Etch 2 Level Aluminum Metallization Rochester Institute of Technology Microelectronic Engineering 29 Channel Engineering Aluminum Aluminum Nitride Spacers P+ Well Contact STI N+ S/D LDD P-SSRW Nitride Spacers P+ Poly N+ Poly P+ S/D TiSi2 N+ Well Contact LDD P+ Well Contact N-SSRW P-Well P+ Poly N+ Poly STI N+ S/D LDD P-SSRW P-Well N-Well N-Substrate P+ S/D TiSi2 N+ Well Contact LDD N-SSRW N-Well N-Substrate Figure 11: Uniformly Doped Twin Wells Figure 12: Super Steep Retrograde Wells Uniformly Doped Twin Wells Super Steep Retrograde Wells NMOS built in p-well o PMOS built in n-well o Set Field VT to stop parasitic conduction channels from forming between adjacent devices o o Rochester Institute of Technology Microelectronic Engineering 2nd step in well formation process o Lower doping at surface which transitions to higher doping sub-surface o Control short channel effects o Set active VT 30 Uniformly Doped Twin Well o In industry, wells are implanted through the trench oxide with energies of 1 MeV to place the peak 1 µm below the surface oThe limit of the Varian 350D Ion Implanter is 190 KeV which is not high enough to implant through 3000 Å of trench oxide o Aluminum Nitride Spacers P+ Poly N+ Poly P+ Well Contact STI N+ S/D LDD P-SSRW P-Well P+ S/D TiSi2 N+ Well Contact LDD N-SSRW N-Well N-Substrate Figure 11: Uniformly Doped Twin Wells Also, there will be non-uniformities in silicon trench depth and TEOS oxide fill. For packing density purposes, multiple active regions are built in the same well with 1 common contact o It is therefore required for the well doping to be continuous under the trench oxide regions o o For this process, the wells will be implanted before the trench oxide fill inRochester theInstitute STIofprocess to ensure the wells are continuous in the field Technology Microelectronic Engineering 31 Uniformly Doped Twin Well Table 3: Field Region VT Field Region FOX 3000 Å NSUB 1x1017 cm-3 VTN 13 V VTP -15 V Aluminum Nitride Spacers P+ Poly N+ Poly P+ Well Contact STI N+ S/D LDD P-SSRW P+ S/D TiSi2 N+ Well Contact LDD N-SSRW P-Well N-Well N-Substrate Figure 11: Uniformly Doped Twin Wells o A drive-in thermal step will create uniform wells with: o ND = 1x1017 cm-3 o XJ-WELL = 1 µm o With a 2.0 V supply, the field-VT is sufficiently large o The junction depth of the wells must be large enough to prevent vertical punch-through between the reverse-biased drain and complimentary doped starting wafer o A junction depth of 1 µm will provide more than enough tolerance Rochester Institute of Technology Microelectronic Engineering 32 Super Steep Retrograde Well Aluminum Nitride Spacers P+ Poly N+ Poly P+ Well Contact STI N+ S/D LDD P-SSRW P-Well P+ S/D TiSi2 N+ Well Contact LDD N-SSRW N-Well N-Substrate Figure 12: Super Steep Retrograde Wells o Increased carrier mobility due to lower channel doping at surface o Increased drive current due to increased mobility o Suppression of short channel effects (SCE) such as VT roll-off, punchthrough, and drain induced barrier lowering (DIBL) due to the higher peek doping sub-surface o Latch-up is suppressed because the base regions of parasitic BJTs are doped higher, therefore reducing their gain. Rochester Institute of Technology 33 Microelectronic Engineering Super Steep Retrograde Well Aluminum Nitride Spacers P+ Poly N+ Poly P+ Well Contact STI N+ S/D LDD P-SSRW P-Well P+ S/D TiSi2 N+ Well Contact LDD N-SSRW N-Well N-Substrate Figure 12: Super Steep Retrograde Wells o Increased carrier mobility due to lower channel doping at surface o Increased drive current due to increased mobility o Suppression of short channel effects (SCE) such as VT roll-off, punchthrough, and drain induced barrier lowering (DIBL) due to the higher peek doping sub-surface o Latch-up is suppressed because the base regions of parasitic BJTs are doped higher, therefore reducing their gain. Rochester Institute of Technology 34 Microelectronic Engineering Super Steep Retrograde Well Lower surface doping concentration Peak channel concentration Uniform well for Field VT Figure 13: Super Steep Retrograde Profile [10] o o o Implanted after uniformly doped wells go through drive-in In Industry, heavy ions that are slow diffusers are used: o Indium (In) is used for p-well of NMOS o Antimony (Sb) or Arsenic (As) are used for n-well of PMOS At RIT, Boron and Phosphorous are available o Boron (B) will be used for p-well of NMOS o Phosphorous (P) will be used for n-well of PMOS o Are more susceptible to transient enhanced diffusion (TED) o Won’t produce profiles as steep as In or Sb but by keeping thermal budget low, can still produce retrograde profiles Rochester Institute of Technology Microelectronic Engineering 35 Unit Process Development Shallow Trench Isolation Channel Engineering Uniformly Doped Twin Well Super Steep Retrograde Well Ultra Thin Gate Oxide Gate Formation Lithography Resist Trimming Reactive Ion Etch (RIE) of Gate Source/Drain/Gate Doping Poly re-ox Low Doped Source/Drain Extensions Sidewall Spacers Source/Drain Contacts Dual Doped Poly Rapid Thermal Dopant Activation Titanium Salicide Contact Cut Etch 2 Level Aluminum Metallization Rochester Institute of Technology Microelectronic Engineering 36 50 Å Gate SiO2 with N2O Incorporation Aluminum Nitride Spacers P+ Poly N+ Poly P+ Well Contact STI N+ S/D LDD P+ S/D TiSi2 N+ Well Contact LDD N-SSRW P-SSRW P-Well N-Well N-Substrate Figure 14: Ultra Thin Gate Oxide o NTRS Roadmap suggests 40 – 50 Å, target for this process is 50 Å o ox = 4 MV/cm, this is at limit of Fowler-Nordheim tunneling o Nitrogen is incorporated into oxide to block diffusion of boron from p+ poly gate into channel of PMOS transistor o Surface Charge Analysis can be done to determine density of interface trap states. Rochester Institute of Technology Microelectronic Engineering 37 Unit Process Development Shallow Trench Isolation Channel Engineering Uniformly Doped Twin Well Super Steep Retrograde Well Ultra Thin Gate Oxide Gate Formation Lithography N-Substrate Resist Trimming Reactive Ion Etch (RIE) of Gate Source/Drain/Gate Doping Poly re-ox Low Doped Source/Drain Extensions Sidewall Spacers Source/Drain Contacts Dual Doped Poly Rapid Thermal Dopant Activation Titanium Salicide Contact Cut Etch 2 Level Aluminum Metallization Aluminum P+ Well Contact Nitride Spacers STI N+ S/D LDD Rochester Institute of Technology Microelectronic Engineering P+ S/D TiSi2 N+ Well Contact LDD N-SSRW P-SSRW P+ Poly N+ Poly P-Well N-Well Figure 15: Poly Gate Formation 38 Gate Formation - Lithography Figure 16: ASML DUV Stepper o o Figure 17: Canon i-line Stepper o Canon FPA-2000i1 stepper ASML PAS 5500/90 stepper o 365 nm i-line source o 248 nm KrF excimer laser o Capable of 0.5 µm lines/spaces o Capable of 0.25 µm lines/spaces Tool is currently down, laser Rochester Institute of Technology Microelectronic Engineering o Standard resist coat/develop track o Capable of 0.05 µm overlay error 39 Gate Formation – Resist Trimming Figure 18: Resist Trimming Process o Resist trimming can be used to make 0.5 µm line a 0.25 µm line for gate o Isotropically etch 1250 Å of resist of sides and top of 0.5 µm line o Resist thickness reduced from 10,000 Å to 8750 Å o This is still sufficiently thick to protect poly during gate plasma etch o Line width reduced to 0.25 µm target in photoresist o This technique will be explored if over-exposing/developing is not successful Rochester Institute of Technology Microelectronic Engineering 40 Gate Formation – RIE Poly o Polysilicon thickness is reduced for smaller gate lengths o 2500 Å target will provide 1:1 aspect ratio for plasma etch o Will block up to 50 keV Phosphorous and 30 keV Boron o Want high selectivity of poly to oxide since oxide is very thin o Reactive Ion Etcher will be used since it etches anisotropically o Etch rate is higher in the vertical direction compared to horizontal o If etch was isotropic, enough under-cut would occur due to lateral etching that 0.25 µm would be etched away and remove the photoresist masking layer Before Etch Rochester Institute of Technology Microelectronic Engineering After Etch Figure 19: Under-Cut of Gate Mask 41 Unit Process Development Shallow Trench Isolation Channel Engineering Uniformly Doped Twin Well Super Steep Retrograde Well Ultra Thin Gate Oxide Gate Formation Lithography Resist Trimming Reactive Ion Etch (RIE) of Gate Source/Drain/Gate Doping Poly re-ox Low Doped Source/Drain Extensions Sidewall Spacers Source/Drain Contacts Dual Doped Poly Rapid Thermal Dopant Activation Titanium Salicide Contact Cut Etch 2 Level Aluminum Metallization Rochester Institute of Technology Microelectronic Engineering 42 Poly Re-Oxidation o After plasma etch of gate there is damage to edges of gate oxide o A 250 Å oxide will be thermally grown to: o Repair damage to gate oxide from plasma etch of the poly gate o Create a thicker screening oxide for source/drain extension implant o Make a thicker etch stop for sidewall spacer etch process o Form an off-set region for lateral diffusion of shallow s/d extension Figure 20: Poly Re-Oxidation o Want to reduce gate overlap of s/d to reduce Miller Capacitance o This capacitance will reduce the cut-off frequency of the device o Need 15 – 20 nm overlap or drive current will degrade [11] Rochester Institute of Technology Microelectronic Engineering 43 Poly Re-Oxidation LPOLY = 250 nm XJ = 75 nm 52.5 nm 52.5 nm LEFFECTIVE = 180 nm Figure 21: Gate Overlap and LEFFECTIVE Calculation o Gate Overlap = 52.5 nm – 25 nm = 27.5 nm o Process is designed for LPOLY = 0.25 µm and LEFFECTIVE = 0.18 µm Rochester Institute of Technology Microelectronic Engineering ≥ 15 – 20 nm requirement 44 Low Doped Source/Drain Extensions Aluminum o Shallow junctions implanted after poly re-ox step o A portion of VDS is dropped across the LDD so a lower effective voltage is across the channel (Eq. 2) Nitride Spacers P+ Poly N+ Poly P+ Well Contact STI N+ S/D LDD P-SSRW P+ S/D TiSi2 N+ Well Contact LDD N-SSRW P-Well N-Well N-Substrate o Figure 22: Low Doped Source/Drain Extensions The advantage of this is reduced hot carrier effects since carriers see lower horizontal electric field Figure 23: Equivalent Circuit with Parasitic Resistance Vchannel = VDS – 2*IDS(Rterminal + Rs/d + RLDD) oThe (Eq. 2) trade-off is there will be a reduction in drive current & switching speed Rochester Institute of Technology Microelectronic Engineering 45 Low Doped Source/Drain Extensions Table 4: NTRS Guidelines for LDD Scaling [6] XJ(LDD) RS (LDD) ND(LDD) NTRS Guidelines 0.4*Lpoly +/- 25% Range 75 nm – 125 nm 400 – 850 sq 5.2x1018 – 2.5 x1018 cm-3 Target 75 nm 400 sq 5.2x1018 cm-3 o Low end of range is chosen for XJ and RS so if more diffusion occurs then is anticipated, the devices will still operate properly o The implant energy must be selected to place the peak of the implant at the Silicon surface. With a 300 Å screening oxide layer: o B11 of 10 keV o P31 of 25 keV o The Varian 350D is capable of implant energies as low as 10 keV o In industry, Silicon (Si) or Germanium (Ge) are implanted before the shallow S/D implants to reduce channeling of dopant ions Rochester Institute of Technology Microelectronic Engineering 46 Silicon Nitride Sidewall Spacers Aluminum Nitride Spacers P+ Poly N+ Poly P+ Well Contact STI N+ S/D LDD P+ S/D TiSi2 N+ Well Contact LDD N-SSRW P-SSRW P-Well N-Well N-Substrate Figure 24: Nitride Sidewall Spacers o Figure 25: SEM Micrograph of Nitride Spacer Sidewall spacers are formed after the LDD implants to create an offset region where a deeper source/drain contact region can be implanted. Re-oxidize Poly Gate Ion Implant LDD Deposit LPCVD Nitride RIE Nitrde to form Spacers Figure 26: Sidewall Spacer Process Rochester Institute of Technology Microelectronic Engineering 47 Silicon Nitride Sidewall Spacers o o In a perfectly anisotropic etch the Lspacer = tpoly = 0.25 µm Parasitic LDD resistance is controlled by length of sidewall spacer RSAT W VDD tox = 4108 µm 0.47 vsat OX VDD VT RLDD W RSLDD LTOTAL (Eq. 3) (Eq. 4) VDD = 2.0 V |VT| = 0.5 V Tox = 50 Å Table 5: Sidewall Spacer Length Effect on Drive Current [9] RSLDD Lspacer LTOTAL Lspacer 2 (/sq) (m) (m) 400 400 400 400 0.1 0.2 0.25 0.3 0.2 0.4 0.5 0.6 ( xm) RLDD W RSAT W 80 160 200 240 1.9% 3.9% 4.9% 5.8% RLDD W o NTRS Guidelines require < 10% reduction in drive current due to parasitic source/drain extension resistance o Source/Drain contact resistance must also be taken into account Rochester Institute of Technology Microelectronic Engineering 48 Source/Drain Contact o Source/Drain contacts implanted after sidewall spacer formation and are self-aligned to the gate Ion Implant Deep S/D Contacts N+/P+ Poly Gates Implanted at same time Figure 27: Source/Drain Contact and Gate Doping o Contact is doped higher and junction depth deeper to decrease parasitic source/drain resistance o Silicide thickness must account for < ½ contact junction depth or increased leakage current will result Rochester Institute of Technology Microelectronic Engineering 49 Source/Drain Contact Table 6: NTRS Guidelines for Source/Drain Contact Scaling [6] XJ(Contact) ND(Contact) RS(Contact) NTRS Guidelines 0.8*LPOLY +/- 33% Range 134 nm – 266 nm Target 150 nm 1x1020 cm-3 50 – 75 /sq o Midpoint of XJ range chosen so XJ-CONTACT ~ 2*XJ-LDD o The implant energy must be ~ 2x higher then shallow LDD implants: o B11 of 20 - 30 keV o P31 of 40 - 50 keV o The sheet resistance of this region must be decreased to decrease the reduction in drive current o The polysilicon gates are doped n+ for NMOS and p+ for PMOS at the same time the contacts are doped. Rochester Institute of Technology Microelectronic Engineering 50 Dual Doped Poly Gates o Dual doped poly is used to create surface channel PMOS transistors by engineering a better matched Metal-Semiconductor work function, MS 4sqNaB V VFB 2 COX ' T B KT Na B ln q ni Qox VFB MS Cox o (Eq. 5) (Eq. 6) (Eq. 7) Retrograde profile will be designed to set appropriate Na for the VT equation in Eq. 5 Rochester Institute of Technology Microelectronic Engineering 51 Dual Doped Poly Gates o Gate depletes body to a depth of WDMAX o Na transitions from 1x1017 cm-3 at surface to 1x1018 cm-3 at the peek o The peak of each profile must be set such that the effective Na the gate depletes is what is required for |VT| = 0.5 V Figure 28: Super Steep Retrograde Profile With WDMAX [10] o Na(effective) for NMOS =6.75x1017 cm-3 o Na(effective) for PMOS = 6x1017 cm-3 o Lower surface concentration, higher sub-surface channel doping and proper VT are all benefits of using a super steep retrograde well Rochester Institute of Technology Microelectronic Engineering 52 Unit Process Development Shallow Trench Isolation Channel Engineering Uniformly Doped Twin Well Super Steep Retrograde Well Ultra Thin Gate Oxide Gate Formation Lithography Resist Trimming Reactive Ion Etch (RIE) of Gate Source/Drain/Gate Doping Poly re-ox Low Doped Source/Drain Extensions Sidewall Spacers Source/Drain Contacts Dual Doped Poly Rapid Thermal Dopant Activation Titanium Salicide Contact Cut Etch 2 Level Aluminum Metallization Rochester Institute of Technology Microelectronic Engineering 53 Rapid Thermal Dopant Activation o Need to repair damage to Si lattice caused by ion implant o Electrically activate dopant atoms o Transient enhanced diffusion will cause dopants to diffuse at accelerated rate and cause deeper then desired junction depths o Rapid Thermal Processing is used to rapidly heat the wafer for a short amount of time o Thermal budget for 0.25 µm device is only 2-3 seconds @ 1000°C Rochester Institute of Technology Microelectronic Engineering Figure 29: Thermal Budget for p+ Junctions 54 Unit Process Development Shallow Trench Isolation Channel Engineering Uniformly Doped Twin Well Super Steep Retrograde Well Ultra Thin Gate Oxide Gate Formation Lithography Resist Trimming Reactive Ion Etch (RIE) of Gate Source/Drain/Gate Doping Poly re-ox Low Doped Source/Drain Extensions Sidewall Spacers Source/Drain Contacts Dual Doped Poly Rapid Thermal Dopant Activation Titanium Salicide Contact Cut Etch 2 Level Aluminum Metallization Rochester Institute of Technology Microelectronic Engineering 55 Titanium Silicide Formation (TiSi2) Aluminum Nitride Spacers P+ Poly N+ Poly P+ Well Contact STI N+ S/D LDD P+ S/D TiSi2 N+ Well Contact LDD N-SSRW P-SSRW P-Well N-Well N-Substrate Figure 30: Titanium Silicide Formation o Want to reduce sheet resistance of source/drain contact regions from 50 – 75 /sq to 4 /sq o Want high drive current for fast switching speeds o Titanium Silicide was widely used at the 0.25 µm node and will be used in this process Rochester Institute of Technology Microelectronic Engineering 56 Titanium Silicide Formation (TiSi2) RC RC TiSi2 Poly Gate RS Rs’ RCH RD’ RD Figure 31: Transistor Cross section with Parasitic Resistances [14] RTOTAL RCHANNEL RPARASITIC RPARASITIC REXTENSION REXTRINSIC REXTENSION RS 'RD' REXTRINSIC RS RD 2RC Rs 'W RSLDD Lspacer RD'W RSLDD Lspacer Rs W RSSILICIDE L RD W RSSILICIDE L RC W Rochester Institute of Technology Microelectronic Engineering C L , C 2 10 9 cm 2 57 Titanium Silicide Formation (TiSi2) o Require < 10% reduction in drive current due to RPARASITIC o Sample calculation shown in Table #, assume: o RS-LDD = 400 /sq LSPACER = 0.25 um o RS-Silcide = 4 /sq LSILICIDE = 0.75 um Table 7: Reduction in Drive Current due to Parasitic Resistance [14] REXT ENSION W REXT RINSIC W RPARASIT IC W RSAT W ( x m) ( x m) ( x m) ( x m) RP ARASITIC W RSAT W 200 7 207 4108 5.1 % o All Resistances are calculated for a nominal 1 µm width o As width is increased, the total resistance components will decrease but the ratio for drive current reduction will remain the same o Drive current is only reduced by ~5% by integrating silicide Rochester Institute of Technology Microelectronic Engineering 58 Titanium Silicide Formation (TiSi2) o Table 8 shows properties for Titanium Silicide reactions Table 8: Titanium Silicide Properties [14] Silicide Thin Film Resistivity (Ω-cm) Sintering Temp (C) Stable on Si up to (C) Reaction with Al at (C) nm of Si consumed per nm of metal nm of resulting silicide per nm of metal TiSi2 (C54) TiSi2 (C49) 13-16 60-70 700-900 500-700 ~900 450 2.27 2.27 2.51 2.51 o 45 nm of Si is consumed by 20 nm of Ti to produce 50 nm of TiSi2 in C49 phase o The C49 phase is a higher resistivity phase created after a 500700°C rapid thermal step o The unreacted Ti is removed by wet chemistry and a 2nd thermal step is performed at 700-900°C to form lower resitivity C54 phase o 50 nm of TiSi2 in the C54 phase should yield an Rs ~ 4 /sq Rochester Institute of Technology Microelectronic Engineering 59 Titanium Silicide Formation (TiSi2) o Titanium Silicide suffers from a narrow line width effect where Rs increases as line width is decreased o This is why the industry transitioned to CoSi2 for sub-0.25 µm CMOS Figure 32: Narrow Line Width Effect [9] o Intel reports an RS of 4 /sq for their 0.25 µm CMOS process, although it is not reported if this is for the source/drain regions only, or gate too o Test structures will be designed on the test chip to observe this effect Rochester Institute of Technology Microelectronic Engineering 60 Unit Process Development Shallow Trench Isolation Channel Engineering Uniformly Doped Twin Well Super Steep Retrograde Well Ultra Thin Gate Oxide Gate Formation Lithography Resist Trimming Reactive Ion Etch (RIE) of Gate Source/Drain/Gate Doping Poly re-ox Low Doped Source/Drain Extensions Sidewall Spacers Source/Drain Contacts Dual Doped Poly Rapid Thermal Dopant Activation Titanium Salicide Contact Cut Etch 2 Level Aluminum Metallization Rochester Institute of Technology Microelectronic Engineering 61 Contact Cut Etch o In a fully scaled 0.25 µm process, contact cut dimensions are 0.25 µm x 0.25 µm o Since Canon FPA-2000i1 stepper will be used, the smallest contact cut dimensions will be 0.5 µm x 0.5 µm o Contact cuts below 2 µm x 2 µm must be dry etched since wet chemistry acid will not go into small holes o Some devices will be designed with the smallest contact cuts that must be plasma etched, while other devices will be designed with larger contact cuts (2 µm or 5 µm) that can be wet etched o Loading is a fabrication phenomena where features with small areas will take longer to clear then large areas. o It is desirable to have all contact cuts for a given design generation to have the same area so that over-etch of smaller contacts will not destroy regions with large areas that clear earlier Rochester Institute of Technology 62 Microelectronic Engineering Unit Process Development Shallow Trench Isolation Channel Engineering Uniformly Doped Twin Well Super Steep Retrograde Well Ultra Thin Gate Oxide Gate Formation Lithography Resist Trimming Reactive Ion Etch (RIE) of Gate Source/Drain/Gate Doping Poly re-ox Low Doped Source/Drain Extensions Sidewall Spacers Source/Drain Contacts Dual Doped Poly Rapid Thermal Dopant Activation Titanium Salicide Contact Cut Etch 2 Level Aluminum Metallization Rochester Institute of Technology Microelectronic Engineering 63 Aluminum Metallization o Multi level metal is necessary to build complex logic circuits that require extensive routing while minimizing real estate Aluminum Nitride Spacers P+ Poly N+ Poly P+ Well Contact STI N+ S/D LDD P-SSRW P-Well P+ S/D TiSi2 N+ Well Contact LDD N-SSRW N-Well N-Substrate Figure 33: 2 Level Aluminum Metallization PECVD TEOS will be deposited as inter-level dielectric layer o Aluminum will be sputter deposited to a thickness ~ 0.5 µm, then patterned and etched by RIE in Chlorine chemistry o A 2nd PECVD TEOS layer will be deposited to insulate Metal 1 from Metal 2, this layer may undergo CMP to reduce topography o Vias will be patterned and etched by RIE in Fluorine plasma o Metal 2 will be sputter deposited to thickness ~ 1.0 µm, then patterned and etched similarly to Metal 1 o Rochester Institute of Technology Microelectronic Engineering 64 Outline RIT/Industry Scaling Trends Gate Control Fundamentals Short Channel Effects Deep-Submicron Scaling Unit Process Development Layout Integration/Fabrication/Test Time Line Questions Rochester Institute of Technology Microelectronic Engineering 65 Layout of Test Chip Number Design Layer 1 2 3 4 5 6 7 8 9 Active n-well Poly N+ select P+ select Contact cut Metal 1 Via Metal 2 Table 9: Test Chip Design Layers Number Lithography Level Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 STI n-well p-well n-SSRW p-SSRW Poly n-LDD p-LDD n+-S/D p+-S/D Contact cut Metal 1 Via Metal 2 1 2 3 4 5 6 7 8 9 10 Mask Level STI n-well p-well Re-use n-well Re-use p-well Poly n-LDD select p-LDD select Re-use n-LDD select Re-use p-LDD select Contact cut Metal 1 Via Metal 2 A new test chip will be designed and mask set fabricated o There are 9 design layers which will be used to create 10 photo masks o These 10 photo masks will be used for 14 lithography levels o In addition to transistors, logic circuits will be designed, as well as capacitors for CV analysis, Van-der-pauw test structures for sheet resistance measurements and Cross-Bridge Kelvin Resistor test structures for measurement of contact resistances o Rochester Institute of Technology Microelectronic Engineering 66 Outline RIT/Industry Scaling Trends Gate Control Fundamentals Short Channel Effects Deep-Submicron Scaling Unit Process Development Layout Integration/Fabrication/Test Time Line Questions Rochester Institute of Technology Microelectronic Engineering 67 Integration/Fabrication/Test o Unit processes will be integrated into a full CMOS manufacturing flow o All fabrication will be done in the Semiconductor and Microsystems Fabrication Laboratory (SMFL) at RIT o When fabrication is completed, the devices will be tested in the Semiconductor Device Characterization lab at RIT o On and off-state performance will be characterized to qualify this process o Electrical parameter extraction will be performed to develop SPICE models for this process which can be used in future circuit designs o The fabrication limits of the SMFL tool set will be pushed so that custom design rules can be created for future layouts Rochester Institute of Technology Microelectronic Engineering 68 Outline RIT/Industry Scaling Trends Gate Control Fundamentals Short Channel Effects Deep-Submicron Scaling Unit Process Development Layout Integration/Fabrication/Test Time Line Questions Rochester Institute of Technology Microelectronic Engineering 69 Time Line ID Task Name 1 Simulation 2 Process Development 3 Layout 4 Fabrication 5 Test 6 Thesis Writing Spring 2005 Summer 2005 Fall 2005 Winter 2005 Spring 2006 Figure 34: Masters Thesis Time Line o This time line constitutes a reasonable plan of study to design, fabricate and test 0.25 µm CMOS transistors o Ample time is left for thesis writing, review, and defense Rochester Institute of Technology Microelectronic Engineering 70 Outline RIT/Industry Scaling Trends Gate Control Fundamentals Short Channel Effects Deep-Submicron Scaling Unit Process Development Layout Integration/Fabrication/Test Time Line Questions Rochester Institute of Technology Microelectronic Engineering 71 References [1] M. Aquilino, “Advancing RIT to Submicron Technology: Design and Fabrication of 0.5 μm NMOS Transistors,” RIT Microelectronic Research Journal, 2004. [2] G. E. Moore, “Cramming more components onto integrated circuits”, Electronics, vol. 38, pp. 114-117, 1965. [3] “Microprocessor Quick Reference Guide.” http://www.intel.com/pressroom/kits/quickreffam.htm [4] Y. Tsividis. Operation and Modeling of The MOS Transistor, 2nd Edition. Oxford University Press, 1999. [5] S. E.Thompson, P. A.Packan, and M. T.Bohr, “Linear versus saturated drive current: Tradeoffs in super steep retrograde well engineering,” Symposium on VLSI Technology Digest, pp. 154-155, 1996. [6] L. Wilson, ed., “The National Technology Roadmap for Semiconductors: 1997 Edition”, Semiconductor Industry Association, San Jose, California [7] De, I.; Osburn, C.M., “Impact of super-steep-retrograde channel doping profiles on the performance of scaled devices,” IEEE Trans. Electron Devices, vol. 46, Issue: 8, pp.1711 - 1717, Aug. 1999 [8] R.C. Jaeger. Introduction to Microelectronic Fabrication, 2nd Edition. Prentice Hall, 2002. [9] S. Wolf. Silicon Processing for the VLSI Era. Volume 4-Deep Submicron Process Technology. Lattice Press, 2002 [10] Q. Xu, “The investigation of key technologies for sub-0.1 μm CMOS device fabrication,” IEEE Trans. Electron Devices, vol. 48, pp. 1412-1420, July 2001. [11] S. Thompson, P. Packan, M. Bohr, “MOS Scaling: Transistor Challenges for the 21st Century”, Intel Technology Journal, 1998. [12] A. Brand, A. Haranahalli, N. Hsieh, Y.C. Lin, G. Sery, N. Stenton, B.J. Woo, S. Ahmed, M. Bohr, S. Thompson, S. Yang, “Intel’s 0.25 Micron, 2.0 Volts Logic Process Technology”, Intel Technology Journal, 1998. [13] “MOSIS SCMOS Technology Codes and Layer Maps SCNA and SCNE”, http://www.mosis.org/Technical/Layermaps/lm-scmos_scna.html [14] http://www.stanford.edu/class/ee311/NOTES/Silicides.pdf Rochester Institute of Technology Microelectronic Engineering 72