The present invention relates to semiconductor devices and methods of fabricating, and more particularly, to a method for achieving a band-edge effective work function using the same metal through a CMOS gate. The present invention is applicable to planar or 3D devices by varying the thickness and nitrogen concentration of the eWF metal.
A “work function” (WF) is generally described as the energy, usually measured in electron volts, needed to remove an electron from the Fermi level to a point immediately outside the solid surface or the energy needed to move an electron from the Fermi level into vacuum. Work function is a material property of any material, whether the material is a conductor, semiconductor, or dielectric. For a metal, the Fermi level lies within the conduction band, indicating that the band is partly filled. For an insulator, the Fermi level lies within the band gap, indicating an empty conduction band; in the case, the minimum energy to remove an electron is about the sum of half the band gap and the electron affinity. An effective work function (eWF) is defined as the work function of metal on the dielectric side of a metal-dielectric interface.
The work function of a semiconductor material can be altered by doping the semiconductor material. For example, undoped polysilicon has a work function of about 4.65 eV, whereas polysilicon doped with boron has a work function of about 5.15 eV. When used as a gate electrode, the work function of a semiconductor or conductor directly affects the threshold voltage of the transistor.
The work function is a key parameter for setting the threshold voltage (Vth) of the CMOS device, whether an n-type FET or a p-type FET. In order to obtain a good electrical control of the FET devices, the work function value should be close to the valence band of the semiconductor for a pFET and close to the conduction band of the semiconductor for an nFET, and more particularly, 5.2 eV and 4.0 eV, respectively for the pFET and nFET in the case of silicon.
Recent technologies have migrated from a gate stack made of silicon oxide (SiO2 or SiON) for the gate dielectric, and polysilicon for the gate electrode, to a high permittivity dielectric (Hk) with SiO2, for gate dielectric and metal layer in order to set up the right effective work function with or without polysilicon forming the gate stack.
Different approaches exist to achieve a particular CMOS device having Hk/MG used in the gate stack. The first one, known as a ‘gate first approach’, is a direct continuity of previous technologies with polysilicon or SiO2: Hk. Metal layers are deposited, and followed by a polysilicon deposition. Then, the stack is selectively etched to obtain the gate electrode. Device junction are formed by way of different implantations followed by an activation anneal (high thermal budget >900° C.). In a second approach, known as ‘gate last approach’, a dummy gate is used as the gate electrode to enable a junction implantation and activation anneal. Further down the process, when devices are fully covered by a thick dielectric to the top of the gate, the dummy gate is removed and replaced by the final gate stack that includes the gate dielectric and the work function metal. With this approach, no high thermal budget (e.g. dopant activation anneal) is applied after the metal, avoiding drift of its WF.
Existing technologies form advanced CMOS devices effectively using additional capping (like aluminum based or Lanthanum based capping) using the same eWF metal in order to achieve the appropriate work function of the p-type and n-type devices to attain the appropriate threshold voltage. The aforementioned process is mainly employed for the ‘gate first approach’ which include a high thermal budget (activation anneal, reaching temperatures higher than 900° C.). The process is relatively complex and extremely sensitive to thermal budget used for the post gate metal depositions.
Certain solutions have been advanced that use different metal thickness, one for the n-type FET, and another for the p-type FET. For a gate first approach, a gate patterning needs to be performed using different metal thicknesses, which are difficult to achieve. Moreover, a high thermal budget (e.g. the dopant activation anneal) is applied following the metal gate deposition, which can significantly affect the eWF. Thus, the process becomes more complex to when applied to CMOS technology.
In other instances, the nitrogen stoichiometry modification of a metal nitride alloy is used to modulate the metal work function to obtain the desired threshold voltage for good device control, i.e., (1−X) atoms of metal associated with X atoms of nitrogen. If X>0.5 the metal nitride alloy is nitrogen rich, if X<0.5 the metal nitride alloy is metal rich. But playing only on nitrogen stoichiometry of a metal nitride alloy it is not sufficient to obtain the right work function needed for both, the n-type and p-type FET transistors. Specially, if it is done using the ‘gate first approach’ with a high thermal budget post-metal deposition (activation anneal), it may drift the metal work function, making it even more difficult to obtain a good threshold voltage for both the nFET and pFET devices.
Certain methods employ different metals or metal alloys for the n-type and p-type devices. Each metal (or metal alloys) is characterized by having its own work function which permits the use of one for the nFET and a different one for the pFET (e.g., TiAl for nFET and TiN for pFET) in order to achieve the appropriate eWF for both devices. However, the integration of different metals increases the complexity of the process. In order to avoid any intermixing of the different metals or impact of a metal on the others (like the eWF of the entire stack), it necessitates removing some of the metal layers on some of the devices (e.g., by leaving it on the nFET and removing it on the pFET). Therefore, it requires a good selectivity among the various metals.
Referring to
Referring to
Accordingly, there is a need for a simple process to create a CMOS device for ‘last approach’ that employs a single metal layer, that is further applicable to the nFET and pFET work function metal and capable of achieving a band-edge or close work function for both types of CMOS transistors.
The present invention will be understood and appreciated more fully from the following detailed description of embodiments thereof taken in conjunction with the accompanying drawings.
In accordance with one embodiment of the present invention, a pFET device is provided with the work function controlled by a thick metal deposition in contrast with a thin layer used to control the WF of an nFET. The thick metal for the pFET device is preferably formed by way of a deposition that extends over the nFET device, wherein by partial etch back on selected areas of the nFET region, the thin metal layer is deposited at the end of the process.
In accordance with an embodiment of the present invention, the pFET device has the work function controlled by way of nitride-metal having a high ratio of nitrogen/metal stoichiometry that is nitrogen-rich (i.e., 1−X atoms of metal for X atoms of nitrogen, wherein X>0.5: e.g., two or more nitrogen atoms for each metal atom), in contrast with the metal-rich metal nitride alloy layer used to control the WF of the nFET device (i.e., 1−X atoms of metal for X atoms of nitrogen, X<0.5: e.g. two or more metal atoms for each atom of nitrogen).
In accordance with an embodiment, the FET device is provided with a metal gate requiring an eWF of the order of 5.2 eV for a p-type FET device, ranging between approximately 4.9 to 5.0 eV and an eWF approximating 4.0 eV for an n-type FET device, and as high as about 4.2 eV. The gate last approach is used, i.e., no high thermal budget >500° C. used for a post metal deposition, the dopant activation anneal having been performed earlier, that permits keeping the metal eWF unchanged and immune to any modification as a result of a high thermal budget. The approach can be used either on planar devices or on 3D devices (like FinFET, tri-gate, and the like), on a Si bulk or an SOI substrate.
In accordance with another embodiment, metals such as Ta, Ti are nitrided in-situ, forming respectively, TiN and TaN. Carbon metal nitride (e.g., TaCN) is used as the only eWF metal applicable to both n-type and p-type CMOS devices. Furthermore, the effective Work Function (eWF) of the metal nitride alloy or carbon metal nitride alloy is controlled by two key parameters: its thickness and the nitrogen/metal stoichiometry of the metal nitride alloy (1−X atoms of metal for X atoms of nitrogen). The thin metal decreases the eWF (<3 nm) whereas a thick metal (>5 nm) increases the eWF. A metal nitride alloy or carbon metal nitride which is metal-rich (1−X atoms of metal for X atoms of nitrogen, wherein X<0.5, e.g., two or more metal atoms for each nitrogen atom) decreases the eWF, and the metal nitride alloy or carbon metal nitride which is nitrogen-rich (1−X atoms of metal for X atoms of nitrogen where X>0.5 e.g. two or more nitrogen atoms for each metal atom) increases the eWF. Consequently, a thin metal-rich metal nitride alloy or carbon metal nitride is preferably used for the n-type FET devices, whereas a thick nitrogen-rich of the same metal nitride alloy or carbon metal nitride is used for the p-type FETs.
According to an embodiment, a complementary metal-oxide-semiconductor (CMOS) structure is provided that includes a semiconductor substrate having nFET and pFET devices respectively built in a first and second region thereof. A high permittivity dielectric layer is deposited on top of the channel, and superimposed to the permittivity dielectric layer. A pFET gate is constructed using a nitrogen-rich thick metal nitride alloy layer or carbon metal nitride layer that provides a controlled WF. Superimposed to the permittivity dielectric layer, the nFET gate is formed including a metal-rich thin metal nitride alloy layer providing a controlled WF, and a metal deposition on top of the respective nitride layers. The thickness of the depositions is variable. The nitrogen ratio of the nitride-metal or carbon metal nitride alloy can be advantageously applied for WF engineering.
The present disclosure relates to forming a pFET device by controlling its work function (WF) employing a thick metal nitride alloy or carbon metal nitride alloy, both of which are nitrogen rich (1−X atoms of metal for X atoms of nitrogen, wherein X>0.5, e.g., two or more nitrogen atoms for each metal atom), and forming a complementary nFET device by controlling its WF employing the same metal nitride alloy or carbon metal nitride alloy, but having a thin layer of the aforementioned metal nitride alloy and which is metal-rich (1−X atoms of metal for X atoms of nitrogen where X<0.5, e.g., two or more metal atoms for each nitrogen atom).
The pFET and nFET transistors thus constructed and method of fabrication will now be described in greater detail by referring to the following description and drawings that accompany the present application. It is noted that the drawings of the present application are provided for illustrative purposes and, as such, they are not drawn to scale.
In the following description, numerous specific details are set forth, such as particular structures, components, materials, dimensions, processing steps and techniques, in order to provide a thorough understanding of the present disclosure. However, it will be appreciated by one of ordinary skill in the art that the present disclosure may be practiced with viable alternative process options without these specific details. In other instances, well-known structures or processing steps have not been described in detail in order to avoid obscuring the various embodiments of the present invention.
In order to have a nitrogen- or metal-rich interface, a metal nitride alloy, nitrogen-rich or metal-rich will be used respectively to setup the eWF of the pFET and nFET devices.
Referring to
Referring to
Referring to
The gate stack preferably includes (from bottom to top), gate dielectric [201] having a thickness approximately 1 to 2 nm, and preferably made of silicon oxide and/or a high permittivity dielectric. The work function metal nitride alloy or nitride carbon metal is selected from TiN, TaN, TaCN and the like, with a filling metal having low resistivity, e.g., Al or W. The same work function metal nitride alloy or carbon metal nitride alloy can be used for both n-type and p-type FET devices. In order to correctly set up eWF and the threshold voltage of the devices, a material rich thin metal nitride alloy or carbon metal nitride alloy is used for the nFET device (<3 nm) [202a]. The nitrogen-rich thick metal nitride alloy or carbon metal nitride alloy is used for the pFET (>5 nm) transistor [202b]. On top of it, a low resistivity conductive material [203] is deposited, such as metal that include Al or W.
Hereinafter, a description follows of a preferred process flow to obtain a metal rich thin metal nitride alloy or carbon metal nitride alloy for the WF metal of the nFET and the nitrogen rich thick metal nitride alloy or carbon metal nitride alloy for the WF metal of the pFET device, that can be obtained advantageously using different paths, of which only one will be described hereinafter.
The preferred process flow is used to form the device, regardless whether a planar, a FinFET or a 3D device, using isolation, a dummy gate, spacer(s) and ion implantation, and a high temperature activation anneal. Activation anneal is done prior the metal gate deposition in order to obtain the aforementioned gate last approach.
Referring to
At this stage, both nFET [105a] and pFET [105b] devices have been formed employing different implantation and activation anneal. The nFET and pFET regions are delimited by shallow trench isolation (STI) [104]. The respective spacers [107] and junction to form the source and drain of the devices are preferably already performed with the help of a dummy gate (not shown) to achieve a proper alignment. Then, a thick dielectric [108] is deposited and planarized, preferably using CMP (chemical mechanical polish). The dummy gate is then removed following the planarization to provide the necessary room to complete the gate stack. A gate dielectric [201] having a thickness of approximately 1 to 2 nm is also present and advantageously formed using SiO2 and/or other high permittivity dielectrics, such as HfO2, ZrO2, and the like.
Following the process flow described with reference to
Referring now to
Referring to
Still referring to
The gate stack of the nFET devices illustrated in
Referring to
The embodiments of the present invention are characterized by the simplicity of the process, by the absence of nFET WF metal on top of the pFET device and by the absence of a pFET WF metal on top of the nFET device. This enables generating significantly more room for the filled metal following the WF metal. It further makes it possible to obtain a low gate resistance, reduce the interfacial resistance thanks to reduction of different number of metal used which is reduced to only two, i.e., WF metal and the filled metal layers, and which also leads to have a lesser nFET/pFET boundary impact in the region where the gate is shared between both FET devices.
While the present disclosure has been particularly shown and described with respect to preferred embodiments thereof, it will be understood by those skilled in the art that the foregoing and other changes in forms and details may be made without departing from the spirit and scope of the present disclosure. It is therefore intended that the present disclosure not be limited to the exact forms and details described and illustrated, but fall within the scope of the appended claims.