The present invention generally relates to semiconductor devices and methods for fabricating semiconductor devices, and more particularly relates to MOS transistors having NiPtSi contact layers and methods for fabricating MOS transistors having NiPtSi contact layers.
Cobalt silicide (CoSi2) has been used widely for contact layers of 90 nm technology metal-oxide-semiconductor (MOS) devices. However, as device size continues to decrease to 65 nm technologies and beyond, the use of CoSi2 becomes more difficult. In particular, the constant reduction in gate dimensions leads to drastic increases in contact resistance because of voiding in the CoSi2 contact. In addition, CoSi2 is relatively incompatible with embedded silicon germanium integration schemes and tends to consume too much silicon associated with silicon-on-insulator (SOI) substrates. Nickel silicide (NiSi) has become a viable alternative to CoSi2. NiSi eliminates the contact resistance problem associated with scaling, is compatible with SiGe substrates, and requires less silicon consumption.
However, NiSi is not without its challenges: 1) the nickel-disilicide (NiSi2) phase has been observed to form at very low temperatures; 2) excessive nickel diffusion has been observed on narrow active areas; and 3) NiSi can be morphologically unstable and can degrade through thermal grooving and agglomeration. The incorporation of platinum (Pt) into NiSi films has been found to delay both the morphological instability of NiSi and the formation of NiSi2, and meets the demanding integration requirements for implementation into high-performance 65 nm technology. In particular, platinum minimizes the number of NiSi2 “pipes” and other defects that form in the nickel-silicide layer. NiSi pipes are silicide defects that propagate from the source/drain active areas under the gate spacer into the gate channel, thus leading to transistor failure.
Incorporation of platinum into a nickel silicide layer poses several challenges. While the presence of platinum in a NiPtSi layer delays agglomeration of NiSi and the formation of the higher resistivity NiSi2 phase, it increases the resistivity of the silicide layer. To keep the resistivity low, NiPtSi layers typically are formed with a platinum concentration of only about 5 at. %. At such low platinum concentrations, the propensity for silicide-induced defect formation increases. Examples of such defects include silicide encroachment under the gate causing shorting in the active areas. Therefore, it is important to deposit a NiPt layer that has an optimum concentration of platinum so that a satisfactory balance between the number of defects and the resistivity of the layer is realized. Further, platinum is expelled from the silicide layer to form nickel disilicide during subsequent rapid thermal annealing (RTA) processes and/or subsequent backend fabrication processes that require high temperatures. Thus, it is important that a sufficient concentration of platinum be incorporated into the silicide layer so that, after subsequent high temperature processes, enough platinum is present in the silicide layer to minimize defects.
Accordingly, it is desirable to provide MOS transistors with silicide contacts that have NiPtSi layers with a platinum concentration that minimizes defects while maintaining low resistivity. In addition, it is desirable to provide MOS transistors that have NiPtSi layers wherein platinum is disposed proximate to a silicon substrate surface for retardation of nickel diffusion. Further, it is desirable to provide methods for fabricating such MOS transistors. Furthermore, other desirable features and characteristics of the present invention will become apparent from the subsequent detailed description of the invention and the appended claims, taken in conjunction with the accompanying drawings and this background of the invention.
A method for fabricating silicide contacts of a semiconductor device in accordance with an exemplary embodiment of the invention is provided. The method comprises providing a silicon substrate having an impurity-doped region disposed at a surface of the silicon substrate. A first layer is sputter-deposited onto the impurity-doped region using a first sputtering target comprising nickel and a first concentration of platinum. A second layer is sputter-deposited onto the first layer using a second sputtering target comprising nickel and a second concentration of platinum, wherein the second concentration of platinum is less than the first.
A method for fabricating an MOS transistor in accordance with an exemplary embodiment of the present invention is provided. The method comprises implanting ions of a conductivity-determining impurity type into a silicon substrate to form an impurity-doped region of the silicon substrate. The impurity-doped region is subjected to a first plasma vapor deposition process using a first sputtering target comprising nickel and a first concentration of platinum in the range of at least about 10 at. % platinum. The impurity-doped region is subjected to a second plasma vapor deposition process using a second sputtering target comprising nickel and a second concentration of platinum that is less than the first concentration of platinum. A NiPtSi layer having an effective concentration of platinum in the range of about 5 at. % to about 20 at. % platinum is formed.
A method for fabricating an MOS transistor in accordance with another exemplary embodiment of the present invention is provided. The method comprises forming a gate stack on a silicon substrate and implanting ions of a conductivity-determining impurity type into the silicon substrate using the gate stack as an implantation mask to form impurity-doped regions of the silicon substrate. The impurity-doped regions are subjected to a first plasma vapor deposition process using a first sputtering target comprising nickel and about 10 at. % to about 50 at. % platinum. The impurity-doped regions are subjected to a second plasma vapor deposition process using a second sputtering target comprising nickel and about 0 at. % to about 10 at. % platinum. The silicon substrate is heated using rapid thermal annealing.
An MOS transistor in accordance with an exemplary embodiment of the present invention is provided. The MOS transistor comprises a gate stack disposed on a silicon substrate, the silicon substrate having a surface. An impurity-doped region is disposed at the surface of the silicon substrate and is self-aligned to the gate stack. An NiPtSi layer is disposed on the impurity-doped region. The NiPtSi layer has an effective concentration of platinum in the range of about 5 at. % to about 20 at. % and has a proportion of platinum atoms within a thickness of the NiPtSi layer proximate to the surface of the silicon substrate that is higher than a proportion of platinum atoms of any other portion of the NiPtSi layer having the same thickness.
The present invention will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements, and wherein:
The following detailed description of the invention is merely exemplary in nature and is not intended to limit the invention or the application and uses of the invention. Furthermore, there is no intention to be bound by any theory presented in the preceding background of the invention or the following detailed description of the invention.
The various embodiments of the present invention result in the fabrication of an MOS transistor with a NiPtSi layer that has an “effective” or average platinum concentration in the range of about 5 at. % to about 20 at. %, preferably less than about 10 at. %. An effective platinum concentration in this range is sufficiently low to provide a desirably low resistivity of the silicide layer. However, the NiPtSi layer has a high proportion of platinum atoms proximate to the surface of the silicon substrate, that is, at the silicide-silicon interface compared to the rest of the NiPtSi layer. This is achieved using a two step plasma vapor deposition (PVD) process. By sputter-depositing a higher concentration of platinum on the surface of the silicon substrate in a first sputtering process and by following with a second sputtering process using a lower platinum concentration, a NiPtSi layer sufficiently thick for electric conductivity is fabricated with a higher proportion of the platinum proximate to the surface of the silicon substrate compared to the rest of the silicide layer. A high concentration of platinum at the silicide-silicon interface is more effective at minimizing the number of defects caused by nickel diffusion and by NiSi2 formation than if the platinum was evenly distributed throughout the NiPtSi layer. Thus, a NiPtSi layer with low resistivity and low defect count and high device yield can be achieved.
Referring to
In the conventional processing, the layer 102 of gate insulating material can be a layer of thermally grown silicon dioxide or, alternatively (as illustrated), a deposited insulator such as a silicon oxide, silicon nitride, or the like. Deposited insulators can be deposited, for example, by chemical vapor deposition (CVD), low pressure chemical vapor deposition (LPCVD), or plasma enhanced chemical vapor deposition (PECVD). Gate insulator layer 102 preferably has a thickness of about 1-10 nm, although the actual thickness can be determined based on the application of the transistor in the circuit being implemented.
A layer of gate electrode material 108 is formed overlying the gate insulating material 102. In accordance with one embodiment of the invention, the gate electrode material is polycrystalline silicon. The layer of polycrystalline silicon is preferably deposited as undoped polycrystalline silicon and is subsequently impurity doped by ion implantation. The polycrystalline silicon can be deposited by LPCVD by the hydrogen reduction of silane. A layer of hard mask material 110, such as silicon nitride or silicon oxynitride, can be deposited onto the surface of the polycrystalline silicon. The hard mask material can be deposited to a thickness of about 50 nm, also by LPCVD. Alternatively, it will be appreciated that a photoresist may be deposited onto the surface of the polycrystalline silicon instead of the hard mask material.
Referring to
After the formation of the reoxidation sidewall spacers 118, a blanket layer 122 of dielectric material is deposited overlying MOS structure 100, as illustrated in
The reoxidation spacers 118 and the offset spacers 124 are used along with the gate stack 112 as an ion implantation mask for formation of source and drain regions 126. By using the gate stack 112 and the spacers 118 and 124 as an ion implantation mask, the source and drain regions are self aligned with the gate stack and the spacers. The source and drain regions are formed by appropriately impurity doping silicon substrate 104 in known manner, for example, by ion implantation of dopant ions, illustrated by arrows 125, and subsequent thermal annealing. For an N-channel MOS transistor the source and drain regions 126 are preferably formed by implanting arsenic ions, although phosphorus ions could also be used. For a P-channel MOS transistor, the source and drain regions are preferably formed by implanting boron ions. MOS transistor 100 then may be cleaned to remove any oxide that has formed on the silicon substrate surface 106. The MOS transistor 100 may be cleaned, for example, by a wet etch chemistry such as buffered hydrofluoric acid (BHF) or dilute hydrofluoric acid.
The method continues with the disposition of the MOS transistor 100 onto a substrate support 134 of a first chamber 130 of a PVD apparatus 128, as illustrated in
Referring to
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In one exemplary embodiment of the invention, if the RTA temperature was not sufficiently high to produce stoichiometric NiPtSi but, rather, a nickel-rich platinum silicide layer was formed, and no subsequent backend fabrication process will be performed at temperatures sufficiently high to convert the nickel-rich platinum silicide to NiPtSi, a second anneal can be performed. In one exemplary embodiment, the second anneal is performed at temperatures in the range of about 400° C. to about 500° C. after the removal of the unreacted nickel platinum and the cap.
Referring to
While at least one exemplary embodiment has been presented in the foregoing detailed description of the invention, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment of the invention, it being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope of the invention as set forth in the appended claims.