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Semiconductor
Manufacturing Technology
T. S. Chao
Dept. of Electrophysics
1/41 1/80
CMOS Process Flow
2/80
Model of Typical Wafer Flow
in a Sub-Micron CMOS IC Fab
Wafer Start
Test/Sort Implant
• Particles
• Metallic Impurities
• Organic Contamination
• Native Oxides
• Electrostatic Discharge
• Contamination often leads to a defective chip. Killer defects are those causes
of failure where the chip on the wafer fails during electrical test.
• It is estimated that 80% of all chip failure are due to killer defects from
contamination.
4/80
Wafer Wet-Cleaning Chemicals
Chemical Mixture Description
Contaminant Name (all Cleans are followed by a DI Chemicals
Water Rinse)
Piranha Sulfuric acid/hydrogen
peroxide/DI water H2SO4/H2O2/H2O
(SPM)
Particles
SC-1 • Ammonium hydroxide/hydrogen
NH4OH/H2O2/H2O
(APM) peroxide/DI water
SC-1 • Ammonium hydroxide/hydrogen
Organics NH4OH/H2O2/H2O
(APM) peroxide/DI water
SC-2 • Hydrochloric acid/hydrogen
HCl/H2O2/H2O
(HPM) peroxide/DI water
Metallics Piranha Sulfuric acid/hydrogen
peroxide/DI water H2SO4/H2O2
(not Cu) (SPM)
DHF • Hydrofluoric acid/water solution
HF/H2O
(will not remove copper)
DHF • Hydrofluoric acid/water solution
HF/H2O
Native Oxides (will not remove copper)
BHF • Buffered hydrofluoric acid NH4F/HF/H2O
5/80
Typical Wafer Wet-Cleaning Sequence
6/80
Diffusion: Simplified Schematic of High-
Temperature Furnace
Thermocouple
Temperature measurements Gas flow
Process gas
controller controller
Quartz tube
Heater 1
Temperature-
setting voltages
Heater 2
Three-zone
Heating
Heater 3 Elements
Exhaust
Pressure
controller
Can do : oxidation, diffusion, deposition, anneals, and alloy
7/80
Dry Oxidation Time (Minutes)
Si (solid) + O2 (gas) SiO2 (solid)
10.0
(100) Silicon
Oxide thickness (µm)
1.0
0.1
0.01
10 102 103 104
Time (minutes)
8/80
Wet Oxygen Oxidation
Exhaust
Gas panel
Furnace
Scrubber
Burn box
• H2+O2 H2O
• Si (solid) + 2H2O SiO2 (solid) + 2H2
• The fast growth rate in wet atmosphere is due to
the faster diffusion and higher solubility of water
vapor than oxygen in silicon dioxide
HCl N2 O2 H2 • Hydrogen molecules produced in the reaction are
trapped in oxide, less dense, using heating
(annealing) to improve.
9/80
Negative Lithography
Photoresist
Oxide Oxide
Silicon substrate Silicon substrate
10/80
Positive Lithography
Ultraviolet light
Areas exposed to
light are dissolved.
Chrome island Shadow on
on glass mask photoresist Island
Window
photoresist
Photoresist
Exposed area
of photoresist
photoresist
Photoresist
oxide
Oxide oxide
Oxide
silicon
Silicon substrate
substrate silicon substrate
Silicon substrate
11/80
Eight Steps of Photolithography
UV Light
λ
HMDS Resist Mask
12/80
Photolithography Bay in a Sub-micron
Wafer Fab
• It is to photograph the image of a circuit pattern onto the photoresist that coats the
wafer surface.
• Yellow fluorescent does not affect photoresist, but sensitive to UV
13/80
Simplified Schematic of a
Photolithography Processing Module
Wafer Stepper
(Alignment/Exposure System)
Vapor Resist Develop- Edge-Bead
Load Station Prime Coat Rinse Removal Transfer Station
Wafer
Cassettes Wafer Transfer System
Note: wafers flow from photolithography into only two other areas: etch and ion implant
14/80
Etch: Dissociation
• Electron collides with a molecule, it can
break the chemical bond and generate free
radicals:
e + AB A+B+ e
• Free radicals have at least one unpaired
electron and are chemically very reactive.
• Increasing chemical reaction rate
• Very important for both etch and CVD.
15/80
Simplified Schematic of Dry Plasma Etcher
• The etch process creates a permanent pattern on the wafer in areas not protected by
the photoresist pattern
• Including: dry etching, wet etching and photoresist stripper
• After dry etching: photoresist stripper + wet cleaning
Cathode electrode
+ R
Chamber wall
Flow of byproducts and
process gases
Positive ion Radical
chemical
Exhaust to
vacuum pump
Vacuum line
16/80
Wet Chemical Isotropic Etch
• Etch profile refers to the shape of the sidewall of the etched
feature
• Isotropic etch profile leads to a undercutting, results in an
undesirable loss of the linewidth
Resist
Film
Substrate
17/80
Anisotropic Etch with Vertical Etch Profile
• The rate of etching is on only one direction perpendicular to the wafer surface
• There is very little lateral etching activity
• This leaves vertical sidewalls, permitting a higher packing density of etched
features on the chip
• With smaller geometries, the etch profiles have higher aspect ratios
• It is difficult to get etchant chemicals in and reaction by-products out of the
high-aspect ratio openings
Anisotropic etch - etches
in only one direction
Resist
Film
Substrate
18/80
Implantation: Common Dopants Used
in Semiconductor Manufacturing
• Doping is the introduction of a dopant into the crystal structure of a
semiconductor material to modify its electronic properties
• Dopants are referred to as impurities
• Two techniques: thermal diffusion and ion implantation (dominant)
Acceptor Dopant Donor Dopant
Semiconductor
Group IIIA Group VA
Group IVA
(P-Type) (N-Type)
Atomic Atomic Atomic
Element Element Element
Number Number Number
Boron (B) 5 Carbon 6 Nitrogen 7
Aluminum 13 Silicon (Si) 14 Phosphorus (P) 15
Gallium 31 Germanium 32 Arsenic (As) 33
Indium 49 Tin 50 Antimony 51
19/80
General Schematic of an Ion Implanter
• Ion source: positive charge
• Extraction assembly: extract ions
• Mass Analyzer: form a beam of the desired dopant ions
• Acceleration column: to attain a high velocity
Ion source
Plasma
Extraction assembly
Analyzing magnet
Acceleration
Ion beam column Process
chamber
Scanning
disk
20/80
Annealing of Silicon Crystal
Ion Beam
• Using Furnace or RTA, hot-wall furnace using high temperature causes extensive
dopant diffusion and is undesirable
• RTA minimizes a phenomenon known as transient enhanced diffusion, to achieve
acceptable junction depth control in shallow implants (~150°C/sec)
21/80
Thin Film Metallization Bay
22/80
Simple Parallel Plate DC Diode Sputtering System
Cathode (-)
Metal target
1) Electric fields + 2) High-energy Ar+ ions
+ +
create Ar+ ions. collide with metal target.
+ +
e-
Gas delivery
e- e-
Argon atoms
3) Metallic atoms are
dislodged from target. Exhaust
Plasma
DC diode sputterer
5) Metal deposits on substrate
Substrate
Anode (+)
23/80
Simplified Schematics of CVD Processing System
Gas inlet
Exhaust
Heat lamps
24/80
Schematic of CVD Transport and
Reaction 8 Steps
1) Mass transport
of reactants CVD Reactor
Gas delivery
7) Desorption of 8) By-product
byproducts removal
2) Film precursor
reactions By-products
Exhaust
3) Diffusion of
gas molecules
5) Precursor
diffusion into 6) Surface reactions Continuous film
4) Adsorption of substrate
precursors
Substrate
25/80
CVD Reaction
26/80
LPCVD Reaction Chamber for Deposition
of Oxides, Nitrides, or Polysilicon
Three-zone heating element
Pressure gauge
Exhaust to
vacuum pump
Gas inlet
Profile thermocouples
(internal)
Spike thermocouples (external, control)
28/80
Schematic of Chemical Mechanical
Planarization (CMP)
Step height: etchback ~ 7000Å vs. CMP ~ 50Å
Downforce
Wafer carrier Polishing pad
Slurry dispenser
Wafer
Polishing
Rotating slurry
platen
Gate
Source Drain
n+ n+
VDD = + 3.0 V
Gate
e- ++++++
++++++
Source ++++++ Drain IDS
n+ n+
Holes Lamp
p-type silicon substrate
e- e-
VDD = + 3.0 V
33/80
Biasing Circuit for a P-Channel MOSFET
S1
Open gate (no charge)
VGG = - 0.7 V
Gate
Source Drain
p+ p+
VDD = -3.0 V
34/80
PMOS Transistor in Conduction Mode
S1
Gate
--------
e- Source
--------
-------- Drain IDS
p+ p+
Electrons
n-type silicon substrate Lamp
e- e-
VDD = - 3.0 V
35/80
Schematic of a CMOS Inverter
+ VDD
S
G
pMOSFET
Input Output
nMOSFET
G
S
- VSS
36/80
Cross-section of CMOS Inverter
37/80
CMOS Manufacturing Steps
1. Twin-well Implants 14
Passivation layer
Bonding pad metal
2. Shallow Trench Isolation ILD-6
3. Gate Structure
ILD-5
4. Lightly Doped Drain Implants M-4
13
5. Sidewall Spacer ILD-4
M-3
6. Source/Drain Implants
ILD-3
12
7. Contact Formation M-2
M-1 10
9. Interlayer Dielectric to Via-1
Via
9 ILD-1
10. First Metal Layer Poly gate
8 LI metal 5 LI oxide
11. Second ILD to Via-2 3
n+ 2 p+ p+ STI n+ n+ p+
12. Second Metal Layer to Via-3 4 6
7 n-well p-well
13. Metal-3 to Pad Etch 1
p- Epitaxial layer
14. Parametric Testing
p+ Silicon substrate
38/80
n-well Formation
Thin
Polish
Films 3 Photoresist
2 3
2
1
Diffusion Photo Etch Oxide 4 n-well
5
5 4 ~5 um
Implant
1 p- Epitaxial layer
p+ Silicon substrate (Dia = 200 mm, ~2 mm thick)
39/80
Mask # 1 : N-well formation
40/80
p-well Formation
• 2nd mask, this mask is the direct opposite of the n-well implant mask
• Boron is 1/3 the mass of P, so 1/3 energy is used.
Boron implant
Thin
Polish
Films 1 Photoresist
1
41/80
Mask # 2 : P-well formation
42/80
STI Trench Etch
STI: shallow trench isolation
+Ions
Thin
Polish
3 Photoresist
Films
4
1 2 3 4 2 Nitride
1 Oxide
Diffusion Photo Etch
n-well p-well
STI trench
Implant p- Epitaxial layer
p+ Silicon substrate
43/80
Mask # 3: Shallow Trench Isolation formation
44/80
STI Oxide Fill
2
2 Thin
Films Polish Trench CVD oxide
1 Nitride
1
Diffusion Photo Etch
n-well p-well
Liner oxide
Implant p- Epitaxial layer
p+ Silicon substrate
45/80
STI Formation
46/80
Poly Gate Structure Process
• Oxide thickness 1.5 ~ 5.0 nm is thermal grown
• Poly-Si ~ 300 nm is doped and deposited in LPCVD using SiH4
• Need Antireflective coating (ARC), very critical
• The most critical etching step in dry etching
3 Photoresist
Polysilicon
Thin deposition 2 ARC 4 Poly gate etch
Polish
Films
1 2 3 4 1 Gate oxide
47/80
Mask # 4 :Poly-Si gate formation
48/80
n− LDD Implant
49/80
Mask # 5: N- LDD formation
50/80
p− LDD Implant
• 6th mask
• In modern device, high doped drain is used to reduce series
resistance. It called S/D extension
51/80
Mask # 6: P- LDD formation
52/80
Side Wall Spacer Formation
Thin Polish
1
Films +Ions
1 Spacer oxide Side wall spacer
2
53/80
n+ Source/Drain Implant
54/80
Mask # 7: N+ Source/Drain formation
55/80
p+ Source/Drain Implant
• 8th mask
• Using rapid thermal anneal (RTA) to prevent dopant
spreading and to control diffusion of dopant
56/80
Mask # 8 : P+ Source/Drain formation
57/80
Contact Formation
• Titanium (Ti) is a good choice for metal contact due to low
resistivity and good adhesion
• No mask needed, called self-align
• Using Ar to sputtering metal
• Anneal to form TiSi2, tisilicide
• Chemical etching to remove unreact Ti, leaving TiSi2, called
selective etching
1 Titanium depostion
58/80
LI Oxide as a Dielectric for Inlaid LI Metal
(Damascene)
• Damascene: a name doped of year ago from a practice that began
thousands ago by artist in Damascus, Syria
LI metal
LI oxide
3
2 Thin 1 Nitride CVD 3 Oxide polish 4 LI oxide etch
Polish
1 Films
LI oxide
4
Diffusion Photo Etch
n-well p-well
60/80
Mask # 9: Local Interconnection formation
61/80
LI Metal Formation
1 2 3 4
Ti/TiN 3 Tungsten 4 LI tungsten polish
2 deposition deposition
Thin Polish
Films
LI oxide
62/80
Via-1 Formation
2
ILD-1
Thin
1 Films Polish
LI oxide
3
Diffusion Photo Etch
n-well p-well
63/80
Mask # 10: Via-1 formation
64/80
Plug-1 Formation
Ti/TiN 3 Tungsten
2 deposition deposition 4Tungsten polish (Plug-1)
1 2 3 4 1 ILD-1
Thin Ti dep.
Films Polish
LI oxide
65/80
SEM Micrographs of Polysilicon,
Tungsten LI and Tungsten Plugs
Tungsten LI Polysilicon
Tungsten
plug
Mag. 17,000 X
66/80
Metal-1 Interconnect Formation
1 2 3
ILD-1
Thin Polish
Films
LI oxide
4
Diffusion Photo Etch
n-well p-well
67/80
Common gate for input
Metal 1, Al
69/80
Via-2 Formation
1 2 3
ILD-1
Thin
Polish
Films
LI oxide
4
Diffusion Photo Etch
n-well p-well
70/80
Mask # 12: Via-2 formation
71/80
Plug-2 Formation
• Ti/TiN/W
• CMP W polish
Tungsten
Ti/TiN Tungsten deposition 3
2 deposition 4 polish (Plug-2)
1 Ti deposition ILD-2
1 2 3 4
ILD-1
Thin Polish
Films
LI oxide
72/80
Metal-2 Interconnect Formation
• Metal 2: Ti/Al/TiN
• ILD-3 gap filling
• ILD-3
• ILD-polish
• Via-3 etch and via deposition, Ti/TiN/W
Metal-2 deposition ILD-3 oxide 4 Via-3/Plug-3 formation
3 polish
1 to etch
2 Gap fill ILD-3
ILD-2
ILD-1
LI oxide
n-well p-well
p- Epitaxial layer
p+ Silicon substrate
73/80
Mask # 13: Metal-2 formation
74/80
Mask # 14: Via-3 formation
75/80
Mask # 15: Metal-3 formation
76/80
CMOS layout (mask 1 to mask 12)
77/80
Full 0.18 µm CMOS Cross Section
Passivation layer
Bonding pad metal
ILD-6
ILD-5
• Passivation layer of M-4
M-3
protect from
ILD-3
moisture, scratched,
M-2
and contamination
ILD-2
• ILD-6 : oxide
M-1
Via
ILD-1
Poly gate
LI metal LI oxide
n+ p+ p+ STI n+ n+ p+
n-well p-well
p- Epitaxial layer
p+ Silicon substrate
78/80
SEM Micrograph of Cross-section of AMD
Microprocessor
Mag. 18,250 X
Micrograph courtesy of Integrated Circuit Engineering
79/80
Wafer Electrical Test using a Micromanipulator Prober
(Parametric Testing)