Reduction of dislocation pile-up formation during relaxed lattice-mismatched epitaxy

Abstract

A semiconductor structure including a cap layer formed over a semiconductor substrate having a rough edge, which discourages formation of dislocation pile-up defects.

Description

FIELD OF THE INVENTION

This invention relates generally to semiconductor substrates and specifically to substrates comprising relaxed lattice-mismatched semiconductor layers.

BACKGROUND

“Virtual substrates” based on silicon (Si) and germanium (Ge) provide a platform for new generations of very large scale integration (VLSI) devices that exhibit enhanced performance in comparison to devices fabricated on bulk Si substrates. The important component of a SiGe virtual substrate is a layer of SiGe that has been relaxed to its equilibrium lattice constant (i.e., one that is larger than that of Si). This relaxed SiGe layer can be directly applied to a Si substrate (e.g., by wafer bonding or direct epitaxy), or atop a relaxed graded SiGe buffer layer in which the lattice constant of the SiGe material has been increased gradually over the thickness of the layer. The SiGe virtual substrate may also incorporate buried insulating layers, in the manner of a silicon-on-insulator (SOI) wafer. To fabricate high-performance devices on these platforms, thin strained layers of semiconductors, such as Si, Ge, or SiGe, are grown on the relaxed SiGe virtual substrates. The resulting biaxial tensile or compressive strain alters the carrier mobilities in the layers, enabling the fabrication of high-speed and/or low-power-consumption devices.

One technique suitable for fabricating strained Si wafers can include the following steps:

• • 1. Providing a silicon substrate that has been edge polished;
  • 2. Epitaxially depositing a relaxed graded SiGe buffer layer to a final Ge composition on the silicon substrate;
  • 3. Epitaxially depositing a relaxed Si_1−xGe_x cap layer having a constant composition on the graded SiGe buffer layer;
  • 4. Planarizing the Si_1−xGe_x cap layer by, e.g., chemical mechanical polishing (CMP);
  • 5. Epitaxially depositing a relaxed Si_1−xGe_x regrowth layer having a constant composition on the planarized surface of the Si_1−xGe_x cap layer; and
  • 6. Epitaxially depositing a strained silicon layer on the Si_1−xGe_x regrowth layer.

The deposition of the relaxed graded SiGe buffer layer enables engineering of the in-plane lattice constant of the SiGe cap layer (and therefore the amount of strain in the strained silicon layer), while reducing the introduction of dislocations. The lattice constant of SiGe is larger than that of Si, and is a direct function of the amount of Ge in the SiGe alloy. As the SiGe graded buffer layer is epitaxially deposited, it will initially be strained to match the in-plane lattice constant of the underlying silicon substrate. However, above a certain critical thickness, the SiGe graded buffer layer will relax to its inherently larger lattice constant.

The process of relaxation occurs through the formation of misfit dislocations at the interface between two lattice-mismatched layers, e.g., a Si substrate and a SiGe epitaxial layer (epilayer). Because dislocations cannot terminate inside a crystal, misfit dislocations have vertical dislocation segments at each end (termed “threading dislocations”), that may rise through the crystal to reach a top surface of the wafer. Both misfit and threading dislocations have stress fields associated with them. As explained by Eugene Fitzgerald et al., Journal of Vacuum Science and Technology B, Vol. 10, No. 4, 1992, incorporated herein by reference, the stress field associated with the network of misfit dislocations affects the localized epitaxial growth rate at the surface of the crystal. This variation in growth rates may result in a surface cross-hatch on lattice-mismatched, relaxed graded SiGe buffer layers grown on Si.

The stress field associated with misfit dislocations may also cause dislocation pile-ups under certain conditions. Dislocation pile-ups are a linear agglomeration of threading dislocations. Because pile-ups represent a high localized density of threading dislocations, they may render devices formed in that region unusable. Inhibiting the formation of dislocation pile-ups is, therefore, desirable.

Dislocation pile-ups are formed as follows. (See, e.g., Srikanth Samavedam et al., Journal of Applied Physics, Vol. 81, No. 7, 1997, incorporated herein by reference.) A high density of misfit dislocations in a particular region of a crystal will result in that region having a high localized stress field. This stress field may have two effects. First, this stress field may present a barrier to the motion of other threading dislocations attempting to glide past the misfits. This pinning or trapping of threading dislocations due to the high stress field of other misfit dislocations is known as work hardening. Second, the high stress field may strongly reduce the local epitaxial growth rate in that region, resulting in a deeper trough in the surface morphology in comparison to the rest of the surface cross-hatch. This deep trough in the surface morphology may also pin threading dislocations attempting to glide past the region of high misfit dislocations. This cycle may perpetuate itself and result in a linear region with a high density of trapped threading dislocations, i.e., dislocation pile-up.

Numerous theories attempt to explain the nucleation of misfit dislocations regarding where they are formed in the crystal and by what process. These theories include: formation at pre-existing substrate dislocations; heterogeneous formation at defects; and homogeneous formation, i.e., formation in defect-free, perfect crystal regions. As explained by Eugene Fitzgerald, Materials Science Reports, Vol. 7, No. 3, 1991, the activation energy for homogeneous dislocation formation is so high that it is unlikely to occur. The most likely source of misfit dislocations in the crystal is heterogeneous nucleation at defects.

As discussed by Petra Feichtinger et al., Journal of the Electrochemical Society, Vol. 148, No. 7, 2001, the substrate edge may provide a significant source of defects that serve as heterogeneous nucleation sites for misfit dislocations. As cut from a boule, the substrate edge may need to be further shaped to enable, for example, the substrate to withstand further mechanical handling. This shaping may be done by an edge grinding operation in which grind wheels that mirror the desired edge contour mechanically remove substrate material along the substrate edge. Various grinding grain sizes may be used, depending on the final edge contour or roughness specifications. The choice of mechanical edge shaping process, as well any additional damage removal steps, strongly influence the extent to which the substrate edge may preferentially serve as a heterogeneous source for misfit dislocation nucleation. The mechanical edge shaping process is also commonly referred to as the “edge contour grinding process” or simply the “grinding process.” Examples of additional damage removal steps include, but are not limited to, no additional steps (i.e., edge is left unpolished), a caustic etch step, or a caustic etch step plus a chemical-mechanical edge polish step. The additional damage removal process is also commonly referred to as the “edge polish process” or simply the “polish process.”

In Feichtinger et al., the authors investigated misfit nucleation formation for p on p+ epitaxial Si, and were interested in preventing the formation of misfit dislocations. Therefore, they preferred a substrate edge finish process that minimized edge defects, and thus minimized the number of heterogeneous misfit nucleation sources.

SUMMARY

The present invention requires the formation of misfit dislocations to fully relax a heteroepitaxial layer comprising, e.g., SiGe, to its inherent lattice constant. To reduce dislocation pile-up, it is preferable to nucleate misfit dislocations uniformly throughout the crystal, thus avoiding localized regions of high misfit dislocation density.

Misfits nucleate at heterogeneous sites, such as imperfections at the substrate edge. In applications, therefore, with few preferred heterogeneous nucleation sites, those particular sites will be responsible for most of the layer relaxation by nucleating a high number of misfit dislocations. The resulting non-uniformity of misfit dislocations may result in pile-ups because the regions of preferred heterogeneous nucleation will have high local concentrations of misfit dislocations.

One might expect that a high-quality polished substrate edge would yield the best quality epitaxial material, i.e., free of dislocation pile-ups. The edge polishing process, however, may not be perfectly uniform. As a result, some local regions along the substrate edge are relatively rougher. These local imperfections have a significantly lower energy barrier for misfit nucleation and therefore serve as effective heterogeneous nucleation sites for misfit dislocations. In this scenario, conditions favor the formation of dislocation pile-ups near the substrate edge because a very limited number of edge sites will nucleate a high number of misfit dislocations during relaxation of the graded SiGe buffer layer. Regions with locally high misfit dislocation densities result in the formation of dislocation pile-ups as discussed above.

In the case of a substrate with a rough edge, however, the entire substrate edge serves as an effective heterogeneous source for nucleation of misfit dislocations. As a result, misfit dislocations are nucleated uniformly everywhere from the substrate edge as the graded buffer layer relaxes. This uniformity helps prevent localized regions of high misfit densities, which in turn reduces the conditions that cause dislocation pile-ups.

In one aspect, the invention features a method for forming a semiconductor structure. A semiconductor substrate is provided having a rough edge. A cap layer is formed over the substrate, the cap layer being substantially relaxed and having a uniform composition, and a lattice constant different from a lattice constant of the semiconductor substrate.

One or more of the following features may be included. The rough edge may have a roughness greater than 10 angstroms. The roughness may be greater than 100 angstroms. The cap layer may have a density of dislocation pile-ups of less than 20/cm. The cap layer may have a threading dislocation density of less than 10⁷/cm². The cap layer may include at least one of a group II, a group III, a group IV, a group V, and a group VI element, such as, for example, silicon and germanium. At least a portion of the cap layer may be formed by growth at a growth temperature greater than 600° C. At least a portion of the cap layer may be annealed at a temperature greater than 600° C. The rough edge may be edge polished after at least a portion of the relaxed cap layer is formed.

A relaxed compositionally graded layer may be formed over the substrate, proximate the relaxed cap layer. The graded layer may have a density of dislocation pile-ups of less than 20/cm. The graded layer may have a threading dislocation density of less than 10⁷/cm². The graded layer may include at least one of a group II, a group III, a group IV, a group V, and a group VI element, such as silicon and germanium. The graded layer may have a grade rate greater than 5% germanium per micrometer and may be graded to a composition of, e.g., 20% germanium, or higher. At least a portion of the graded layer may be formed by growth at a growth temperature greater than 600° C. At least a portion of the graded layer may be annealed at a temperature greater than 600° C. The rough edge may be polished after at least a portion of the graded layer is formed.

Providing the semiconductor substrate with the rough edge may include roughening the edge of the semiconductor substrate.

A tensilely strained layer may be formed over the relaxed cap layer. At least a portion of the relaxed cap layer may be planarized prior to the formation of the tensilely strained layer. A relaxed compositionally graded layer may be formed over the substrate, proximate the relaxed cap layer. The rough edge may be edge polished after at least a portion of the graded layer is formed. The rough edge may be polished after at least a portion of the relaxed cap layer is formed.

In another aspect, the invention features a method for forming a semiconductor structure. A semiconductor substrate is provided having a rough edge. A cap layer is formed over the substrate, the cap layer being substantially relaxed and having a uniform composition, and a lattice constant different from a lattice constant of the semiconductor substrate. A p-type metal-oxide-semiconductor (PMOS) transistor is formed by: (i)forming a gate dielectric portion over a portion of the relaxed cap layer, (ii) forming a gate over the gate dielectric portion, the gate including a conducting layer, and (iii) forming a source and a drain proximate the gate dielectric portion, the source and drain including p-type dopants.

In yet another aspect, the invention features a method for forming a semiconductor structure. A semiconductor substrate is provided having a rough edge; a cap layer is formed over the substrate, the cap layer being substantially relaxed and having a uniform composition, and a lattice constant different from a lattice constant of the semiconductor substrate. An n-type metal-oxide-semiconductor (NMOS) transistor is formed by (i) forming a gate dielectric portion over a portion of the relaxed cap layer, (ii) forming a gate over the gate dielectric portion, the gate including a conducting layer, and (iii) forming a source and a drain proximate the gate dielectric portion, the source and drain including n-type dopants.

In another aspect, the invention features a method for forming a semiconductor structure. A semiconductor substrate is provided having a rough edge. A cap layer is formed over the substrate, the cap layer being substantially relaxed and having a uniform composition, and a lattice constant different from a lattice constant of the semiconductor substrate. A p-type metal-oxide-semiconductor (PMOS) transistor is formed by: (i) forming a first gate dielectric portion over a first portion of the relaxed cap layer, (ii) forming a first gate over the first gate dielectric portion, the first gate including a first conducting layer, and (iii) forming a first source and a first drain proximate the first gate dielectric portion, the first source and first drain including p-type dopants. An n-type metal-oxide-semiconductor (NMOS) transistor is formed by (i) forming a second gate dielectric portion over a second portion of the relaxed cap layer, (ii) forming a second gate over the second gate dielectric portion, the second gate including a second conducting layer, and (iii) forming a second source and a second drain proximate the second gate dielectric portion, the second source and second drain including n-type dopants.

In another aspect, the invention features a semiconductor structure. The structure includes a semiconductor substrate, and a cap layer disposed over the substrate, the cap layer being substantially relaxed, having a uniform composition, a lattice constant different from the lattice constant of the semiconductor substrate, and a lower density of dislocation pile-ups proximate an edge of the cap layer than a density of dislocation pile-ups present proximate an edge of a cap layer formed under similar conditions on a substrate having a polished edge.

One or more of the following features may also be included. The density of dislocation pile-ups of the cap layer may be less than the density of dislocation pile-ups present proximate an edge of a cap layer formed under similar conditions on a substrate having an edge with a roughness less than 10 angstroms. The cap layer may have a density of dislocation pile-ups of less than 20/cm. The cap layer may have a threading dislocation density of less than 10⁷/cm². The cap layer may include at least one of a group II, a group III, a group IV, a group V, and a group VI element, such as, e.g., silicon and germanium. At least a portion of the cap layer may be formed by growth at a growth temperature greater than 600° C. At least a portion of the cap layer may be annealed at a temperature greater than 600° C.

A compositionally graded layer may be disposed proximate the cap layer, with the graded layer being substantially relaxed. The graded layer may have a density of dislocation pile-ups of less than 20/cm. The graded layer may have a threading dislocation density of less than 10⁷/cm². The graded layer may include at least one of a group II, a group III, a group IV, a group V, and a group VI element, such as silicon and germanium. The graded layer may have a grade rate greater than 5% germanium per micrometer. The graded layer may be graded to a concentration of 20% germanium, or higher. At least a portion of the graded layer may be formed by growth at a growth temperature greater than 600° C. At least a portion of the graded layer may be annealed at a temperature greater than 600° C.

A tensilely strained layer may be disposed over the cap layer. The tensilely strained layer may include at least one of a group II, a group III, a group IV, a group V, and a group VI element. At least a portion of the cap layer may be planarized. A relaxed compositionally graded layer may be disposed over the substrate, proximate the cap layer. The substrate may include a polished substrate edge and the graded layer may include a polished layer edge.

In another aspect, the invention features a semiconductor structure including a semiconductor substrate. A cap layer is disposed over the substrate, the cap layer being substantially relaxed, and having a uniform composition, and a lattice constant different from a lattice constant of the semiconductor substrate. A p-type metal-oxide-semiconductor (PMOS) transistor is disposed over the relaxed cap layer. The PMOS transistor includes (i) a gate dielectric portion disposed over a portion of the relaxed cap layer, (ii) a gate disposed over the gate dielectric portion, the gate including a conducting layer, and (iii) a source and a drain disposed proximate the gate dielectric portion, the source and first drain including p-type dopants.

In another aspect, the invention features a semiconductor structure including a semiconductor substrate. A cap layer is disposed over the substrate, the cap layer being substantially relaxed, and having a uniform composition, and a lattice constant different from a lattice constant of the semiconductor substrate. An n-type metal-oxide-semiconductor (NMOS) transistor is disposed over the relaxed cap layer. The NMOS transistor includes (i) a gate dielectric portion disposed over a portion of the relaxed cap layer, (ii) a gate disposed over the gate dielectric portion, the gate including a conducting layer, and (iii) a source and a drain disposed proximate the gate dielectric portion, the source and drain including n-type dopants.

In another aspect, the invention features a semiconductor structure including a semiconductor substrate. A cap layer is disposed over the substrate, the cap layer being substantially relaxed, and having a uniform composition, and a lattice constant different from a lattice constant of the semiconductor substrate. A p-type metal-oxide-semiconductor (PMOS) transistor is disposed over the relaxed cap layer, the PMOS transistor including (i) a first gate dielectric portion disposed over a first portion of the relaxed cap layer, (ii) a first gate disposed over the first gate dielectric portion, the first gate including a first conducting layer, and (iii) a first source and a first drain disposed proximate the first gate dielectric portion, the first source and first drain including p-type dopants. An n-type metal-oxide-semiconductor (NMOS) transistor is disposed over the relaxed cap layer. The NMOS transistor includes (i) a second gate dielectric portion disposed over a second portion of the relaxed cap layer, (ii) a second gate disposed over the second gate dielectric portion, the second gate including a second conducting layer, and (iii) a second source and a second drain disposed proximate the second gate dielectric portion, the second source and second drain including n-type dopants.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1-4 are schematic cross-sectional views of alternative embodiments of a semiconductor structure fabricated on a substrate; and

FIG. 5 is a schematic cross-sectional view of a complementary-metal-oxide-semiconductor (CMOS) device fabricated on the substrate illustrated in FIG. 3.

Like-referenced features represent common features in corresponding drawings.

DETAILED DESCRIPTION

In an embodiment, creation of misfit dislocations is controlled by postponing the wafer edge-polishing step until after the growth of a relaxed graded buffer layer, preferably before a wafer-surface planarization step. Referring to FIG. 1, a substrate 10 suitable for use with the invention comprises a semiconductor, such as silicon. Several layers collectively indicated at 11 are formed on substrate 10. In contrast to conventional processes, substrate 10 is not edge polished prior to the formation of layers 11. Layers 11 may be grown, for example, in any suitable epitaxial deposition system, including, but not limited to, atmospheric-pressure CVD (APCVD), low- (or reduced-) pressure CVD (LPCVD), ultra-high-vacuum CVD (UHVCVD), or by molecular beam epitaxy (MBE). The epitaxial growth system may be a single-wafer or multiple-wafer batch reactor. The growth system may also utilize a low-energy plasma to enhance the layer growth kinetics. Layers 11 and substrate 10 may be referred to together as “semiconductor wafer 13.”

Layers 11 may include a relaxed graded buffer layer 12 disposed over substrate 10. Graded buffer layer 12 may include group IV elements such as SiGe, graded to a final composition of, for example, 10%-100% Ge, i.e., ranging from Si_{0 9}Geo_0.1 to pure Ge, with a grading rate of, for example, 5% Ge/micrometer (μm) of thickness, or a higher grading rate, with a thickness T₁ of, for example, 0.2-20 μm, a threading dislocation density of less than, e.g., 10⁷/cm², and grown or annealed, for example, at temperatures higher than 600° C., including, in some embodiments, at temperatures higher than 900° C. In alternative embodiments, graded buffer layer 12 may include group III and group V elements, such as indium (In), gallium (Ga), arsenic (As), and phosphorous (P), and/or group II and group VI elements, such as zinc (Zn), cadmium (Cd), selenium (Se), and tellurium (Te).

A relaxed cap layer 14 may be disposed over graded buffer layer 12. Relaxed cap layer 14 may include, for example, Si_1−xGe_x with a constant composition containing, for example, 10-100% Ge, (i.e., 0.1≦x≦1.0) having a thickness T₂ of, e.g., 0.1-2 μm. Relaxed cap layer 14 may have a threading dislocation density of less than, e.g., 10⁷/cm², and it may be grown or annealed, for example, at temperatures higher than 600° C., including, in some embodiments, at temperatures higher than 900° C. In an alternative embodiment, relaxed cap layer 14 may be formed directly on substrate 10, without graded buffer layer 12. In some embodiments, relaxed cap layer 14 may include group III and group V elements, such as gallium arsenide (GaAs) and/or group II and group VI elements, such as zinc selenide (ZnSe). Relaxed cap layer 14 may have a lattice constant that is different from a lattice constant of substrate 10. For example, relaxed cap layer 14 may be formed from Si_0.8Ge_0.2 having a lattice constant of 5.472 angstroms (Å), over a substrate 10 formed of Si and having a lattice constant of 5.431 Å. In this example, the lattice constant of Si_0.8Ge_{0 2} was calculated assuming endpoint lattice constants of 5.431 Å for Si and 5.658 Å for Ge, and using the Dismukes correction for the nonlinear dependence of the SiGe lattice constant on composition. (See, e.g., Dismukes et al., The Journal of Physical Chemistry Vol. 68, No. 10, 3021-3027, 1964, incorporated herein by reference.)

A tensilely strained layer 18 may be disposed over relaxed cap layer 14, sharing an interface 15 with relaxed cap layer 14. In an embodiment, tensilely strained layer 18 is formed of silicon. In other embodiments, tensilely strained layer 18 may be formed of SiGe, or at least one of a group II, a group III, a group V, and a group VI element. Tensilely strained layer 18 may have a thickness T₃ of, for example, 50-500 Å.

In certain embodiments, relaxed cap layer 14 may be planarized prior to the formation of tensilely strained layer 18. Relaxed cap layer 14 may be planarized by, for example, CMP. In certain embodiments, tensilely strained layer 18 may be formed directly on a planarized surface of relaxed cap layer 14.

Referring to FIG. 2, in another embodiment, a relaxed regrowth layer 17 having a constant composition may be formed over the planarized surface of cap layer 14, and tensilely strained layer 18 may be subsequently formed over regrowth layer 17. Regrowth layer 17 may include, for example, Si_1−xGe_x with a constant composition containing, for example, 10-100% Ge (i.e., 0.1≦x ≦1.0) and having a thickness T₄ of, e.g., 0.1-2 μm. In some embodiments, relaxed regrowth layer 17 may include group III and group V elements, such as gallium arsenide (GaAs) and/or group II and group VI elements, such as zinc selenide (ZnSe).

Substrate 10 may be provided with a rough outer face or edge 20, having a roughness greater than that of an edge polished substrate. Rough edge 20 has a dull appearance, with a root-mean-square (RMS) roughness greater than, e.g., 10 Å. In some embodiments, the roughness of rough edge 20 is greater than 100 Å, e.g., 200 Å-700 Å, or even greater. The roughness of rough edge 20 may be measured with a commercially available system such as the MP2000+ Surface Analyzer, available from Chapman Instruments, Inc. (Rochester, NY). The roughness of rough edge 20 is inherently present in substrate 10 when, for example, substrate 10 is cut from a boule traditionally formed by the Czochralski method, and is subjected to the conventional mechanical edge shaping process described above. Preserving the roughness of rough edge 20 on substrate 10 may be preferred during the formation of relaxed graded buffer layer 12 and at least a portion of relaxed cap layer 14 because the roughness of rough edge 20 inhibits the formation of dislocation pile-ups. For example, by forming graded buffer layer 12 and relaxed cap layer 14 on substrate 10 having rough edge 20, the dislocation pile-up density in each of graded buffer layer 12 and relaxed cap layer 14 may be less than 20/cm. This low dislocation pile-up density is enabled by the uniform creation of misfit dislocations starting at substrate rough edge 20. By way of comparison, graded buffer layer 12 and/or relaxed cap layer 14 grown on substrate 10 having rough edge 20 will have a lower dislocation pile-up density near the wafer edge than graded buffer layer 12 and/or relaxed cap layer 14 grown on substrate 10 having polished edge 20.

Defect densities may be measured in SiGe by, for example, using a conventional chromic acid-based Schimmel etch. (See, e.g., Journal of the Electrochemical Society, Vol. 126:479 (1979), incorporated herein by reference.). Threading dislocation densities are calculated by examining the etched sample with an optical microscope operated in differential interference contrast, i.e., Nomarski, mode, and counting the number of etch pits per unit area located away from dislocation pile-ups (i.e. not trapped in dislocation pile-ups), yielding units of inverse area (cm⁻²). Dislocation pile-up densities are calculated by measuring the total length of dislocation pile-ups per unit area, yielding units of inverse length (cm⁻¹).

In some embodiments, the as-grown boule may have a polished edge, or boule processing steps may result in a substrate with a polished edge. It may then be desirable to roughen the substrate edge prior to forming at least graded buffer layer 12. The edge could be roughened, for example, by using appropriate grit sizes in the mechanical edge shaping process.

Edge 30, including substrate rough edge 20, may be left unpolished, including after the formation of layers 11. In some applications, however, semiconductor wafer 13 having a polished edge 30 may be preferred. Therefore, after the formation of relaxed graded buffer layer 12 on substrate 10 having rough edge 20, edge 30 (including rough edge 20) may be polished to meet other requirements for further processing such as, for example, CMOS processing. Edge 30 may be polished by various techniques, to achieve a smooth surface with a shiny, mirror-like appearance. These techniques may include, but are not limited to, a caustic etch step, or a caustic etch step in combination with chemical-mechanical edge polishing with, e.g., a silica slurry. These polishing steps reduce the roughness of edge 30, and thereby provide the polished edge required for some applications. Because the polishing takes place after the formation of relaxed graded buffer layer 12, however, formation of dislocation pile-ups near wafer edge 30 in graded buffer layer 12 is avoided.

Polishing semiconductor wafer edge 30 after formation of relaxed graded buffer layer 12 but before the formation of tensilely strained layer 18 may provide the additional benefit of creating a higher kinetic barrier to relaxation for tensilely strained layer 18, because polished edge 30 will make the nucleation of misfit dislocations more difficult. This may be desirable because, although graded buffer layer 12 needs to be substantially relaxed, tensilely strained layer 18 may need to remain substantially strained.

Referring to FIG. 3 as well as to FIG. 1, in some embodiments, a compressively strained layer 16 may be disposed between relaxed cap layer 14 and tensilely strained layer 18, sharing an interface 19 with tensilely strained layer 18. In an embodiment, the compressively strained layer includes Si_1−yGe_y with a Ge content (y) higher than the Ge content (x) of relaxed Si_1−xGe_x cap layer 14. Compressively strained layer 16 may contain, for example, 30-100% Ge (i.e., 0.3≦y≦1.0) and have a thickness T₅ of, e.g., 50-500 Å. Edge 20 of substrate 10 or edge 30 of substrate 10 and layers 11 may be kept rough during relaxed graded buffer layer 12 formation to reduce dislocation pile-ups, as described above. In an alternative embodiment (not shown), compressively strained layer 16 may be disposed between relaxed regrowth layer 17 and tensilely strained layer 18.

Referring to FIG. 4, in an alternative embodiment, semiconductor wafer 13 may include relaxed layer 14 formed directly on substrate 10, without first forming relaxed graded buffer layer 12 (see, e.g., FIG. 1). Relaxed layer 14 could be formed directly on substrate 10 by, for example, epitaxial deposition, or by wafer bonding and layer transfer.

The present invention has been observed by Nomarski microscopy. Nomarski optical images illustrated a region of the wafer edge of an epitaxial structure including Si substrate 10 with a fully relaxed SiGe graded buffer layer 12 graded to 20% Ge, and a SiGe 20% relaxed cap layer 14 containing 20% Ge. The epitaxial structure was grown on a polished edge 20 Si substrate 10. Graded buffer layers and cap layers were measured to be >99% relaxed by asymmetric (224) glancing-incidence- and glancing-exit-angle x-ray diffraction scans. The high density of dislocation pile-ups caused by the use of a polished-edge 20 substrate 10 was readily observed using Nomarski microscopy as non-uniformities, i.e., breaks, in the otherwise well-behaved cross-hatched surface morphology.

In contrast, in the same structure grown on Si substrate 10 with rough edge 20, the cross-hatch surface morphology was uniform, and no pile-ups were present, in contrast to the structure grown on Si substrate 10 with polished edge 20. The use of substrate 10 with rough edge 20 demonstrably reduced the formation of dislocation pile-ups.

Semiconductor wafers 13 having layers 11 disposed over substrate 10, processed as described above with reference to FIGS. 1, 2, and 3, may be used for the fabrication of various devices, including, for example, CMOS devices and circuits. Referring to FIG. 5, a p-type metal-oxide-semiconductor (PMOS) transistor 32 is formed in a first region 34 of semiconductor wafer 13. An n-type well 36 is formed in layers 11 in first region 34. An n-type metal-oxide-semiconductor (NMOS) transistor 38 is formed in a second region 40 of semiconductor wafer 13. PMOS transistor 32 and NMOS transistor 38 include, respectively, a first gate dielectric portion 42 disposed over a first portion of relaxed cap layer 14 and a second gate dielectric portion 44 disposed over a second portion of relaxed cap layer 14. First and second gate dielectric portions 42, 44 may comprise a gate oxide such as silicon dioxide. A first gate 46 is disposed over first gate dielectric portion 42, and a second gate 48 is disposed over second gate dielectric portion 44. First and second gates 46, 48 may be formed from a conductive material, such as doped polysilicon. A first source 50 and a first drain 52 (defined for purposes of illustration by the interior boundaries) are formed in first region 34, proximate first gate 46. First source 50 and first drain 52 may be formed by the implantation of p-type ions, such as boron. PMOS transistor 32 includes first source 50, first drain 52, first gate 46, and first dielectric portion 42. A second source 54 and a second drain 56 (defined for purposes of illustration by the interior boundaries) are formed in second region 40, proximate second gate 48. Second source 54 and second drain 56 may be formed by the implantation of n-type ions, such as phosphorus. NMOS transistor 38 includes second source 54, second drain 56, second gate 48, and second dielectric portion 44.

In some embodiments, maintaining a rough edge on semiconductor wafer 13, as described above with reference to FIGS. 1-4, may reduce dislocation pile-ups only in regions close to substrate edges 20. It may be preferable, therefore, to control layer growth parameters to also reduce dislocation pile-up defects in a center region of semiconductor wafer 13. Dislocation pile-up densities may be reduced not only by control of the roughness of substrate edge 20 but also by, for example, growing layers at a slower rate, grading relaxed graded buffer layer 12 at a lower rate, and/or growing layers at a higher temperature.

Notwithstanding the foregoing examples, it should be stressed that the invention is applicable to a wide range of epitaxial growth conditions, including but not limited to any combination of precursor source gases or liquids (such as, for example, silane, dichlorosilane, trichlorosilane, silicon tetrachloride, germane, and germanium tetrachloride), any growth pressure, any growth temperature, any layer growth rate, and any graded buffer layer grade rate.

The invention may be embodied in other specific forms without departing from the spirit of essential characteristics thereof. The foregoing embodiments are therefore to be considered in all respects illustrative rather than limiting on the invention described wherein.

Claims

1. A method for forming a semiconductor structure, comprising the steps of: providing a semiconductor substrate having a top surface and a rough edge angled away from the surface;thereafter growing a cap layer over the top surface of the substrate, the cap layer being substantially relaxed, having a uniform composition, and having a lattice constant different from a lattice constant of the semiconductor substrate; andpolishing the rough edge of the substrate after at least a portion of the cap layer is grown.

2. The method of claim 1, wherein the cap layer has a density of dislocation pile-ups of less than 20/cm.

3. The method of claim 1, wherein the cap layer has a threading dislocation density of less than 107/cm2.

4. The method of claim 1, wherein the cap layer comprises at least one of a group II, a group III, a group IV, a group V, and a group VI element.

5. The method of claim 4, wherein the cap layer comprises silicon and germanium.

6. The method of claim 5, wherein the cap layer comprises approximately 20% germanium.

7. The method of claim 1, wherein at least a portion of the cap layer is formed by growth at a growth temperature greater than 600° C.

8. The method of claim 7, wherein at least a portion of the cap layer is formed at a growth temperature greater than 900° C.

9. The method of claim 1, further comprising: annealing at least a portion of the cap layer at a temperature greater than 600° C.

10. The method of claim 9, wherein the portion of the cap layer is annealed at a temperature greater than 900° C.

11. The method of claim 1, wherein providing the semiconductor substrate with the rough edge comprises roughening the edge of the semiconductor substrate.

12. The method of claim 1, further comprising: forming a strained layer over the relaxed cap layer.

13. The method of claim 12, further comprising: planarizing at least a portion of the relaxed cap layer prior to the formation of the strained layer.

14. The method of claim 12, further comprising: forming a relaxed compositionally graded layer over the substrate, proximate the relaxed cap layer.

15. The method of claim 1, further comprising: forming a p-type metal-oxide-semiconductor (PMOS) transistor by: (i) forming a gate dielectric portion over a portion of the relaxed cap layer,(ii) forming a gate over the gate dielectric portion, the gate comprising a conducting layer,(iii) forming a source and a drain proximate the gate dielectric portion, the source and drain including p-type dopants.

16. The method of claim 1, further comprising: forming an n-type metal-oxide-semiconductor (NMOS) transistor by: (i) forming a gate dielectric portion over a portion of the relaxed cap layer,(ii) forming a gate over the gate dielectric portion, the gate comprising a conducting layer,(iii) forming a source and a drain proximate the gate dielectric portion, the source and drain including n-type dopants.

17. The method of claim 1-further comprising: forming a p-type metal-oxide-semiconductor (PMOS) transistor by: (i) forming a first gate dielectric portion over a first portion of the relaxed cap layer,(ii) forming a first gate over the first gate dielectric portion, the first gate comprising a first conducting layer,(iii) forming a first source and a first drain proximate the first gate dielectric portion, the first source and first drain including p-type dopants; and forming an n-type metal-oxide-semiconductor (NMOS) transistor by:(i) forming a second gate dielectric portion over a second portion of the relaxed cap layer,(ii) forming a second gate over the second gate dielectric portion, the second gate comprising a second conducting layer,(iii) forming a second source and a second drain proximate the second gate dielectric portion, the second source and second drain including n-type dopants.

18. The method of claim 1, wherein the rough edge of the substrate defines an edge plane, the top surface defines a surface plane, and the edge plane and the surface plane are non-coplanar.

19. The method of claim 1, wherein the substrate has a bottom surface and the rough edge is disposed between the top and bottom surfaces.

20. A method for forming a semiconductor structure, comprising the steps of: providing a semiconductor substrate having a top surface and a rough edge angled away from the surface;thereafter forming a relaxed compositionally graded layer over the top surface of the substrate;polishing the rough edge of the substrate after at least a portion of the graded layer is formed; andforming a cap layer over the graded layer, the cap layer being substantially relaxed, having a uniform composition, and having a lattice constant different from a lattice constant of the semiconductor substrate,wherein the graded layer is proximate the relaxed cap layer.

21. The method of claim 20, wherein the graded layer has a density of dislocation pile-ups of less than 20/cm.

22. The method of claim 20, wherein the graded layer has a threading dislocation density of less than 107/cm2.

23. The method of claim 20, wherein the graded layer comprises at least one of a group II, a group III, a group IV, a group V, and a group VI element.

24. The method of claim 23, wherein the graded layer comprises silicon and germanium.

25. The method of claim 24, wherein the graded layer has a grade rate greater than 5% germanium per micrometer.

26. The method of claim 20, wherein the graded layer is graded to a concentration of 20% germanium.

27. The method of claim 20, wherein at least a portion of the graded layer is formed by growth at a growth temperature greater than 600° C.

28. The method of claim 27, wherein at least a portion of the graded layer is formed at a growth temperature greater than 900° C.

29. The method of claim 20, further comprising: annealing at least a portion of the graded layer at a temperature greater than 600° C.

30. The method of claim 29, wherein the portion of the graded layer is annealed at a temperature greater than 900° C.

31. The method of claim 20, wherein the rough edge of the substrate defines an edge plane, the top surface defines a surface plane, and the edge plane and the surface plane are non-coplanar.

32. The method of claim 20, wherein the substrate has a bottom surface and the rough edge is disposed between the top and bottom surfaces.

33. A method for forming a semiconductor structure, the method comprising the steps of: providing a semiconductor substrate having a top surface and a rough edge angled away from the surface;thereafter forming a relaxed compositionally graded layer over the top surface of the substrate;forming a cap layer proximate the graded layer, the cap layer being substantially relaxed, having a uniform composition, and having a lattice constant different from a lattice constant of the semiconductor substrate;forming a strained layer over the relaxed cap layer; andpolishing the rough edge of the substrate after at least a portion of the graded layer is formed.

34. The method of claim 33, wherein the rough edge is polished after at least a portion of the relaxed cap layer is formed.

35. The method of claim 33, wherein the rough edge of the substrate defines an edge plane, the top surface defines a surface plane, and the edge plane and the surface plane are non-coplanar.

36. The method of claim 33, wherein the substrate has a bottom surface and the rough edge is disposed between the top and bottom surfaces.

37. A method for forming a semiconductor structure, comprising the steps of: providing a semiconductor substrate having a top surface and a rough outer face not coplanar with the top surface;thereafter growing a cap layer over the top surface of the substrate, the cap layer being substantially relaxed, having a uniform composition, and having a lattice constant different from a lattice constant of the semiconductor substrate; andpolishing the rough outer face of the substrate after at least a portion of the cap layer is grown.

38. The method of claim 37, wherein the rough outer face is substantially perpendicular to the top surface.

39. A method for forming a semiconductor structure, comprising the steps of: providing a semiconductor substrate having a top surface and a rough outer face not coplanar with the top surface;thereafter forming a relaxed compositionally graded layer over the top surface of the substrate;polishing the rough outer face of the substrate after at least a portion of the graded layer is formed; andforming a cap layer over the graded layer, the cap layer being substantially relaxed, having a uniform composition, and having a lattice constant different from a lattice constant of the semiconductor substrate,wherein the graded layer is proximate the relaxed cap layer.

40. The method of claim 39, wherein the rough outer face is substantially perpendicular to the top surface.

41. A method for forming a semiconductor structure, the method comprising the steps of: providing a semiconductor substrate having a top surface and a rough outer face not coplanar with the top surface;thereafter forming a relaxed compositionally graded layer over the top surface of the substrate;forming a cap layer proximate the graded layer, the cap layer being substantially relaxed, having a uniform composition, and having a lattice constant different from a lattice constant of the semiconductor substrate;forming a strained layer over the relaxed cap layer; andpolishing the rough outer face of the substrate after at least a portion of the graded layer is formed.

42. The method of claim 41, wherein the rough outer face is substantially perpendicular to the top surface.

43. A method for forming a semiconductor structure, comprising the steps of: providing a semiconductor substrate having a top surface, a bottom surface, and a rough outer face disposed between the top and bottom surfaces;thereafter growing a cap layer over the top surface of the substrate, the cap layer being substantially relaxed, having a uniform composition, and having a lattice constant different from a lattice constant of the semiconductor substrate; andpolishing the rough outer face of the substrate after at least a portion of the cap layer is grown.

44. A method for forming a semiconductor structure, comprising the steps of: providing a semiconductor substrate having a top surface, a bottom surface, and a rough outer face disposed between the top and bottom surfaces;forming a relaxed compositionally graded layer over the top surface of the substrate having the rough edge; andforming a cap layer over the graded layer, the cap layer being substantially relaxed and having a uniform composition, and having a lattice constant different from a lattice constant of the semiconductor substrate,wherein the rough outer face has a roughness greater than 10 angstroms.

45. A method for forming a semiconductor structure, comprising the steps of: providing a semiconductor substrate having a top surface, a bottom surface, and a rough outer face disposed between the top and bottom surfaces;thereafter forming a relaxed compositionally graded layer over the top surface of the substrate;polishing the rough outer face of the substrate after at least a portion of the graded layer is formed; andforming a cap layer over the graded layer, the cap layer being substantially relaxed, having a uniform composition, and having a lattice constant different from a lattice constant of the semiconductor substrate,wherein the graded layer is proximate the relaxed cap layer.

46. A method for forming a semiconductor structure, the method comprising the steps of: providing a semiconductor substrate having a top surface defining a surface plane, a bottom surface, and a rough outer face disposed between the top and bottom surfaces;thereafter forming a relaxed compositionally graded layer over the top surface of the substrate;forming a cap layer proximate the graded layer, the cap layer being substantially relaxed, having a uniform composition, and having a lattice constant different from a lattice constant of the semiconductor substrate;forming a strained layer over the relaxed cap layer; andpolishing the rough outer face of the substrate after at least a portion of the graded layer is formed.