Expanding the toolbox of atomic scale processing
- Author
- Tahsin Faraz
- Year
- 2019
- Abstract & Cover
- Source of Information
- Harm Knoops
- University
- Eindhoven University of Technology (Eindhoven, Netherlands)
- External Link
- Read Thesis
As we enter an era of atomic scale device dimensions, it has become imperative to utilize deposition and etching techniques that allow for processing materials at the atomic level. Furthermore, next-generation devices consist of various material layers across both planar and three-dimensional (3D) layouts which has led to an additional need for processing materials in a selective manner. As a result, it is now vitally important to retain proper control over the thickness and properties of materials grown or removed during fabrication of nanoscale devices with 3D geometries. Plasmaenhanced atomic layer deposition (ALD) has obtained a prominent position in synthesizing ultra-thin films of functional materials with atomic scale precision. Uniform and conformal film deposition even on challenging 3D substrate topographies can be attained by virtue of the sequential and self-limiting precursor and plasma exposure steps of plasma ALD. Highly reactive plasma radicals are generated during the plasma step and the contribution of these electrically neutral species toward film growth is a well-known feature of plasma ALD. However, the ions generated during plasma exposure can also play a significant role in the deposition process which has been relatively less explored. Furthermore, the challenges related to current plasma based dry-etching processes provide a window of opportunity for being potentially tackled by the etch counterpart of ALD, i.e., atomic layer etching (ALE). This dissertation investigates plasma-enhanced atomic scale processing of functional materials and the role of ions during these processes on planar and 3D substrate topographies, relevant for next-generation device technologies. In the first part of this work, a new ALD process for SiNx was developed using a novel organosilane precursor (DSBAS) and N2 plasma. Dense and wet-etch resistant SiNx films that can be synthesized at low temperatures serve as spacers or encapsulation layers for protecting sensitive device components; e.g., gate stacks in 3D transistors or magnetic tunnel junctions in emerging magnetoresistive memories. SiNx films with a high density and low impurity content were obtained at low substrate temperatures on planar substrates using the process developed in this work. Deposition were also performed on high aspect ratio 3D trench nanostructures to investigate SiNx film conformality and wet-etch resistance. Sources limiting conformality on 3D substrates were attributed to factors occurring in the N2 plasma step. Identification of factors associated with plasma processing conditions is a prerequisite for addressing the challenge of growing conformal SiNx on 3D substrates. Yet, very low wet-etch rates were observed at different regions throughout the trenches, confirming high quality SiNx could be grown at low substrate temperature on 3D substrates using the developed process. Next, the effects substrate biasing during plasma ALD on the properties of materials (oxides and nitrides of Ti, Hf, and Si) grown on planar and 3D substrate topographies were investigated. A commercial 200-mm remote plasma ALD system equipped with RF substrate biasing was used to control the ion energy during the plasma exposure step. This technique was demonstrated to significantly enhance the versatility of plasma ALD processes by providing additional knobs for controlling a wide range of material properties, appropriate for numerous applications. Substrate biasing during plasma ALD increased the refractive index and mass density of TiOx and HfOx and enabled control over their crystalline properties. Plasma ALD of these oxides with substrate biasing formed crystalline films at a low temperature which would otherwise yield amorphous films without biasing. Substrate biasing drastically reduced the resistivity of conductive TiNx and HfNx films. Furthermore, biasing enabled the residual stress of these materials to be altered from tensile to compressive. The properties of SiOx were slightly improved whereas those of SiNx were degraded as a function of substrate biasing. Plasma ALD on 3D trench nanostructures with biasing induced differing film properties at different regions of the 3D substrate which demonstrated the potential of this technique in enabling new approaches for topographically selective deposition. Ion energy characteristics on grounded and biased substrates during plasma exposure were also measured to investigate their role in tailoring material properties. Insights from such measurements are essential toward understanding how a given plasma ALD process at different operating conditions can be influenced by energetic ions. Ion flux-energy distribution functions (IFEDFs) were measured using a retarding field energy analyzer for reactive plasmas typically used in plasma ALD (O2, H2, N2) without and with RF biasing. The properties of materials (TiOx, HfNx, SiNx) grown using these plasmas were analyzed as a function of the ion energy and flux parameters derived from IFEDFs. These results have provided more insight on the relation between energetic ions and the ensuing material properties, e.g., by providing energy maps of material properties in terms of the ion energy dose during plasma ALD. They demonstrate how the measurement and control of ion energy characteristics during plasma ALD provide a platform for synthesizing ultra-thin films with the desired properties. In the final part of this work, past research efforts on ALE were reviewed and the key defining characteristics of ALE identified. These include cyclic step-wise processing, self-limiting surface chemistry, repeated removal of atomic layers (not necessarily a full monolayer) of the material, and the presence or absence of directional species that lead to anisotropic or isotropic ALE processes, respectively. Subsequently, further parallels were drawn with the more mature and mainstream technology of ALD from which lessons and concepts were extracted that can be beneficial for advancing the field of ALE. To conclude, this dissertation elucidates important aspects associated with plasmaenhanced atomic scale processes that provide deeper insight on the fundamental and technological opportunities afforded by these techniques, relevant for future 3D device architectures. It serves to exemplify how the properties of functional materials can be tailored by accurate control and optimization of plasma based processing conditions