The present disclosure relates to formation of Ni-doped cobalt silicide films by sputter deposition utilizing a Ni-doped cobalt deposition source, e.g., a sputtering target, and to Ni-doped cobalt deposition sources, e.g., sputtering targets. The disclosure enjoys particular utility in the formation of high integration density semiconductor integrated circuit (IC) devices including active devices such as MOS transistors.
The escalating requirements for high density and performance associated with ultra-large scale integration (ULSI) devices necessitate design rules of 0.18 μm and below, such as 0.15 μm and below, increased transistor and circuit speeds, high reliability, and increased manufacturing throughput. The reduction of design features, e.g., of source, drain, and gate regions of transistors formed in or on a common semiconductor substrate, challenges the limitations of conventional contact and interconnection technology, including conventional photolithographic, etching, and deposition techniques.
As a result of the ever-increasing demand for large-scale and ultra-small dimensioned integrated semiconductor devices, self-aligned techniques have become the preferred technology for forming such devices in view of their simplicity and capability of high-density integration. As device dimensions decrease in the deep sub-micron range, both vertically and laterally, many problems arise, especially those caused by an increase in sheet resistance of the contact areas to the source and drain regions and junction leakage as junction layer thickness decreases. To overcome this problem, the use of self-aligned, highly electrically conductive refractory metal silicides, i.e., salicide processing, has become commonplace in the manufacture of integrated circuit semiconductor devices comprising, e.g., MOS type transistors.
Salicide processing involves deposition of a metal that forms an intermetallic compound with silicon, but does not react with silicon oxides, nitrides, or oxynitrides under normal processing conditions. Refractory metals commonly employed in salicide processing include titanium (Ti), nickel (Ni), and cobalt (Co), each of which forms very low resistivity phases with silicon (Si), e.g., TiSi2, NiSi2, and CoSi2.
Deposition of the refractory metals commonly employed in salicide processing, i.e., titanium (Ti), nickel (Ni), and cobalt (Co), each of which forms very low resistivity phases with silicon (Si), e.g., TiSi2, NiSi2, and CoSi2, involves physical vapor deposition (PVD), preferably cathode sputter deposition utilizing a sputtering target, e.g., a magnetron target, comprised of ultra-pure Ti, Ni, or Co. Co is a preferred material for use in silicide/salicide processing in view of the low resistivity and stability of CoSi2. 5N purity Co sputtering targets containing <˜6 ppm Ni, and generally termed “Ni-free”, are typically utilized in silicide/salicide processing. Disadvantageously, however, such Ni-free 5N purity Co targets are extremely costly to manufacture, primarily due to the difficulty in separating certain elements therefrom, notably Ni, which occur in nature together with Co. More specifically, separation of Ni from Co to reduce Ni levels to <˜6 ppm, as required in the fabrication of Ni-free 5N purity Co deposition source material, requires much additional effort and incurs significantly increased cost. Consequently, current practices for forming high integration density semiconductor IC devices have high manufacturing costs related to the costly nature of the consumable 5N purity Co sputtering targets utilized therein.
In view of the foregoing, there exists a clear need for improved, less costly means and methodology for performing Co-based silicide/salicide processing utilized in the manufacture of high integration density semiconductor IC devices and other devices requiring deposition of Co layers suitable for silicide/salicide processing.
An advantage of the present disclosure is an improved method of forming a layer of an electrically conductive refractory metal material.
Another advantage of the present disclosure is an improved method of forming a layer of electrically conductive Ni-doped Co silicide.
Yet another advantage of the present disclosure is an improved method of forming an electrically conductive contact to a semiconductor device, e.g., a MOS transistor.
Still another advantage of the present disclosure is an improved semiconductor device, e.g., a MOS transistor, comprising a contact layer of electrically conductive Ni-doped Co silicide.
A further advantage of the present disclosure is an improved physical vapor deposition (PVD) source, e.g., a sputtering source, comprising Ni-doped Co.
Additional advantages and other features of the present disclosure will be set forth in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from the practice of the present disclosure. The advantages of the present disclosure may be realized and obtained as particularly pointed out in the appended claims.
According to an aspect of the present disclosure, the foregoing and other advantages are obtained in part by an improved method of forming a layer of an electrically conductive refractory metal-silicide material, comprising steps of:
(a) providing a Si-containing workpiece;
(b) forming a Ni-doped Co layer on a surface of the workpiece; and
(c) reacting the Ni-doped Co layer and workpiece to form a layer of electrically conductive Ni-doped Co silicide.
According to embodiments of the present disclosure, step (b) comprises forming the Ni-doped Co layer by means of a physical vapor deposition (PVD) process utilizing a Ni-doped Co deposition source, for example, depositing the Ni-doped Co layer by sputter deposition, e.g., magnetron sputtering, utilizing a Ni-doped Co target.
Embodiments of step (b) according to the present disclosure include utilizing a 10 ppm≦Ni≦105 ppm Ni-doped Co deposition source, preferably a 10 ppm≦Ni≦104 ppm Ni-doped Co deposition source, more preferably a 10 ppm≦Ni≦500 ppm Ni-doped Co deposition source; whereby step (c) respectively comprises forming a Ni-doped Co silicide layer with 10 ppm≦Ni≦105 ppm, preferably a Ni-doped Co silicide layer with 10 ppm≦Ni≦104 ppm, more preferably a Ni-doped Co silicide layer with 10 ppm≦Ni≦500 ppm.
According to embodiments of the present disclosure, step (a) comprises providing a semiconductor device precursor including at least one active device; and step (c) comprises forming an electrically conductive contact layer on the at least one active device. Preferably, step (a) comprises providing a semiconductor device precursor including at least one MOS transistor; and step (c) is a salicide process comprising forming electrically conductive contact layers over at least one of gate electrode and source and drain regions of the at least one MOS transistor.
Another aspect of the present disclosure is a Si-based semiconductor device, comprising a Ni-doped Co silicide layer formed over at least a portion of at least one active region of the device.
According to preferred embodiments of the present disclosure, the device comprises at least one MOS transistor with a Ni-doped Co silicide layer formed over at least one of gate electrode and source and drain regions of the transistor; and the Ni-doped Co silicide layer has 10 ppm≦Ni≦105 ppm, preferably 10 ppm≦Ni≦104 ppm, more preferably 10 ppm≦Ni≦500 ppm.
A further aspect of the present disclosure is an improved physical vapor deposition (PVD) source comprising Ni-doped Co, wherein 10 ppm≦Ni≦105 ppm, preferably 10 ppm≦Ni≦104 ppm, more preferably 10 ppm≦Ni≦500 ppm.
Preferably, the PVD source is a sputtering target, e.g., a magnetron sputtering target.
Additional advantages and aspects of the present disclosure will become readily apparent to those skilled in the art from the following detailed description, wherein embodiments of the present disclosure are shown and described, simply by way of illustration of the best mode contemplated for practicing the present disclosure. As will be described, the present disclosure is capable of other and different embodiments, and its several details are susceptible of modification in various obvious respects, all without departing from the spirit of the present disclosure. Accordingly, the drawing and description are to be regarded as illustrative in nature, and not as limitative.
The following detailed description of the present disclosure can best be understood when read in conjunction with the following drawings, in which the various features (e.g., layers) are not necessarily drawn to scale but rather are drawn as to best illustrate the pertinent features, and like reference numerals are employed throughout to designate similar features, wherein:
According to salicide processing, a refractory metal is deposited in uniform thickness over all exposed upper surface features of a Si wafer by means of a physical vapor deposition (PVD) process, preferably cathode sputter deposition utilizing an ultra-pure sputtering target and an ultra-high vacuum, multi-chamber DC magnetron sputtering system. In MOS transistor formation, deposition is generally performed after gate etch and source/drain junction formation. In a less common variant, source/drain junction formation is effected subsequent to refractory metal layer deposition via dopant diffusion through the refractory metal layer into the underlying semiconductor. In either case, after deposition, the refractory metal layer blankets the top surface of the gate electrode, typically formed of heavily-doped polysilicon, the silicon oxide, nitride, or oxynitride sidewall spacers on the opposing side surfaces of the gate electrode, the silicon oxide isolation regions formed in the silicon substrate between adjacent active device regions, and the exposed surfaces of the substrate where the source and drain regions are formed or will be subsequently formed. As a result of thermal processing, e.g., a rapid thermal annealing process (RTA) typically performed in an inert atmosphere, the refractory metal reacts with underlying Si to form electrically conductive silicide layer portions on the top surface of the polysilicon gate electrode and on the exposed surfaces of the substrate where source and drain regions are or will be formed. Unreacted portions of the refractory metal layer, e.g., on the silicon oxide, nitride, or oxynitride sidewall spacers and the silicon oxide isolation regions, are then removed, as by a wet etching process selective to the metal silicide portions. In some instances, e.g., with Co, a first RTA step may be performed at a relatively lower temperature in order to form first-phase CoSi which is then subjected to a second RTA step performed at a relatively high temperature to convert the first-phase CoSi to second-phase, lower resistivity CoSi2.
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As indicated supra, deposition of high purity cobalt (Co) layers utilized in forming very low resistivity CoSi2 layers, as in salicide processing for forming electrical contacts in the manufacture of high integration density semiconductor IC and other semiconductor devices, typically involves physical vapor deposition (PVD), preferably cathode sputter deposition utilizing a sputtering target, e.g., a magnetron target, comprised of ultra-pure Co. Co is a preferred material for use in silicide/salicide processing in view of the low resistivity and stability of CoSi2. 5N purity Co sputtering targets containing <˜6 ppm Ni, and generally designated as “Ni-free”, are typically utilized in silicide/salicide processing. Disadvantageously, however, such Ni-free 5N purity Co targets are extremely costly to manufacture, primarily due to the difficulty in separating certain elements therefrom, notably Ni, which occur in nature together with Co. In particular, separation of Ni from Co to reduce Ni levels to <˜6 ppm, i.e., “nickel-free” levels, as required in the fabrication of “Ni-free” 5N purity Co deposition source material, requires much additional effort and incurs significantly increased cost. Consequently, current practices for forming high integration density semiconductor IC devices and other types of semiconductor devices have high manufacturing costs related to the costly nature of the consumable 5N purity Co sputtering targets utilized therein.
The present disclosure, therefore, has as aims the provision of lower cost Ni-based PVD sources, e.g., sputtering targets, suitable for use in the manufacture of high integration density semiconductor IC devices and other types of semiconductor devices requiring very low resistivity CoSi2 layers, and improved, lower cost methodology for forming such high integration density semiconductor IC devices and other types of semiconductor devices requiring very low resistivity CoSi2 layers.
Briefly stated, the present disclosure is based upon the discovery that very low resistivity CoSi2 layers exhibiting excellent performance characteristics, e.g., as contacts, in IC and other semiconductor device applications can be readily and conveniently formed by use of Ni-doped Co PVD sources, e.g., sputtering sources such as magnetron targets, which Ni-doped Co PVD sources are fabricated at significantly reduced cost vis-à-vis conventional Ni-free (i.e., <6 ppm Ni) PVD sources, primarily due to elimination of the requirement for use of very costly processing techniques and methodologies for reducing Co levels in Ni to achieve “Ni-free” purity levels, i.e., <6 ppm Ni. The use of significantly lower cost Ni-doped Co consumable PVD sources, e.g., sputtering targets, afforded by the present disclosure advantageously translates into lower manufacturing costs of IC and other semiconductor devices.
As utilized throughout the present disclosure and claims, the term “Ni-doped Co” refers to Co containing a minor amount of Ni, i.e., greater than the <6 ppm Ni present in Ni-free Co, i.e., ≧˜10 ppm, but not >˜105 ppm. According to the present disclosure, Ni-doped Co material suitable for use as PVD sources, e.g., sputtering targets, may be formed in different ways, e.g., by limiting removal of Ni naturally occurring in Co during conventional metal refining to achieve a desired Ni level ≧˜10 ppm, hence reducing processing costs, or by introducing an additional amount of Ni to low-doped Co containing Ni to achieve a desired Ni dopant level ≧˜10 ppm.
An illustrative, but non-limitative silicide/salicide process utilizing a Ni-doped Co PVD source, i.e., a magnetron sputtering target comprised of Ni-doped Co, generally corresponds to the process illustrated in
(a) providing a Si-containing workpiece;
(b) forming a Ni-doped Co layer on a surface of the workpiece; and
(c) reacting the Ni-doped Co layer and workpiece to form a layer of electrically conductive Ni-doped Co silicide.
According to embodiments of the present disclosure, step (b) comprises forming the Ni-doped Co layer by means of a physical vapor deposition (PVD) process utilizing a Ni-doped Co deposition source, for example, by depositing the Ni-doped Co layer by sputter deposition in conventional manner as shown in
Step (c) comprises forming a Ni-doped Co silicide layer in conventional manner as described above in connection with the description of
The Ni-doped Co silicide layers formed according to the present disclosure exhibit properties/characteristics which are fully compatible with the requirements of the product devices, including very low resistivity and thermal stability.
More specifically, according to exemplary embodiments of the present disclosure, step (a) comprises providing a semiconductor device precursor including at least one active device; and step (c) comprises forming an electrically conductive contact layer on the at least one active device. Preferably, step (a) comprises providing a semiconductor device precursor including at least one MOS transistor; and step (c) preferably is a salicide process comprising forming electrically conductive contact layers over at least one of gate electrode and source and drain regions of the at least one MOS transistor.
Another aspect of the present disclosure is a Si-based semiconductor device, such as formed via the above-described process, comprising a Ni-doped Co silicide layer formed over at least a portion of at least one active region of the device. Preferably, the device comprises at least one MOS transistor with a Ni-doped Co silicide layer formed over at least one of gate electrode and source and drain regions of the transistor. By way of illustration only, the amount of Ni dopant in the Ni-doped silicide layer may be 10 ppm≦Ni≦105 ppm, preferably 10 ppm≦Ni≦104 ppm, more preferably 10 ppm≦Ni≦500 ppm, depending upon the Ni content of the Ni-doped Co PVD source utilized for the process methodology.
A further aspect of the present disclosure is improved physical vapor deposition (PVD) sources comprising Ni-doped Co. By way of illustration, the amount of Ni dopant in the PVD source may be 10 ppm≦Ni≦105 ppm, preferably 10 ppm≦Ni≦104 ppm, more preferably 10 ppm≦Ni≦500 ppm. Preferably, the PVD source is in the form of a sputtering target, e.g., a magnetron sputtering target.
In summary, the present disclosure provides significantly lower cost Ni-based PVD sources, e.g., sputtering targets, which lower cost PVD sources advantageously facilitate lower cost manufacture of high integration density semiconductor IC devices and other types of semiconductor devices. The Ni-doped Co PVD sources provided by the present disclosure enjoy particular use in the formation of highly electrically conductive silicide contact layers to active semiconductor devices (e.g., MOS transistors), as by salicide processing methodology.
In the previous description, numerous specific details are set forth, such as specific materials, structures, processes, etc., in order to provide a better understanding of the present of the present disclosure. However, the present disclosure can be practiced without resorting to the details specifically set forth herein. In other instances, well-known processing techniques and structures have not been described in order not to unnecessarily obscure the present disclosure.
Only the preferred embodiments of the present disclosure and but a few examples of its versatility are shown and described in the present disclosure. It is to be understood that the present disclosure is capable of use in various other combinations and environments and is susceptible of changes and/or modification within the scope of the concept(s) as expressed herein.