Plasma etching processes at the 22 nm technology node and below will have to satisfy multiple stringent scaling requirements of microelectronics fabrication. To satisfy these requirements simultaneously, significant improvements in controlling key plasma parameters are essential. Pulsed plasmas exhibit considerable potential to meet the majority of the scaling challenges, while leveraging the broad expertise developed over the years in conventional continuous wave plasma processing. Comprehending the underlying physics and etching mechanisms in pulsed plasma operation is, however, a complex undertaking; hence the full potential of this strategy has not yet been realized. In this review paper, we first address the general potential of pulsed plasmas for plasma etching processes followed by the dynamics of pulsed plasmas in conventional high-density plasma reactors. The authors reviewed more than 30 years of academic research on pulsed plasmas for microelectronics processing, primarily for silicon and conductor etch applications, highlighting the potential benefits to date and challenges in extending the technology for mass-production. Schemes such as source pulsing, bias pulsing, synchronous pulsing, and others in conventional high-density plasma reactors used in the semiconductor industry have demonstrated greater flexibility in controlling critical plasma parameters such as ion and radical densities, ion energies, and electron temperature. Specifically, plasma pulsing allows for independent control of ion flux and neutral radicals flux to the wafer, which is key to eliminating several feature profile distortions at the nanometer scale. However, such flexibility might also introduce some difficulty in developing new etching processes based on pulsed plasmas. Therefore, the main characteristics of continuous wave plasmas and different pulsing schemes are compared to provide guidelines for implementing different schemes in advanced plasma etching processes based on results from a particularly challenging etch process in an industrial reactor.

In this work, experimental measurements of the electronic band gap of low-k organosilicate dielectrics will be presented and discussed. The measurement of bandgap energies of organosilicates will be made by examining the onset of inelastic energy loss in core-level atomic spectra using X-ray photoelectron spectroscopy. This energy serves as a reference point from which many other facets of the material can be understood, such as the location and presence of defect states in the bulk or at the interface. A comparison with other measurement techniques reported in the literature is presented. V C 2014 AIP Publishing LLC.

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Pulsed rf plasmas show promise to overcome challenges for plasma etching at future technological nodes. In pulsed plasmas, it is important to characterize the transient phenomena to optimize plasma processing of materials. In particular, it is important to evaluate the effect of the ion energy and angular distribution (IEAD) functions during pulsing on etching of nanoscale features. In this work, the impact of simultaneous pulsing of both source and bias in an inductively coupled plasma on plasma characteristics and feature profile evolution is discussed using results from a two-dimensional reactor scale plasma model coupled to a Monte Carlo based feature profile model. Results are discussed for an Ar∕Cl2 gas mixture which is typically used for poly-Si etching. The consequences of duty cycle, pulse shape, and the phase lag between source and bias power pulses on discharge characteristics, IEADs to the wafer, and feature profile evolution are discussed. The low plasma density during the initial period of the pulse was found to introduce a high energy tail component to the IEADs. This high energy tail component can be affected by modifying the pulse shape. The Si etching rate is found to increase with increasing duty cycle but is lower compared to continuous mode of operation due to lower time averaged power deposition. Pulsing the source and bias out of phase provides for increased ion energies and fluxes to the wafer for a given duty cycle.

Plasma oxidation of the c-Si substrate through a very thin gate oxide layer can be observed during HBr/O2/Ar based plasma overetch steps of gate etch processes. This phenomenon generates the so-called silicon recess in the channel and source/drain regions of the transistors. In this work, the authors compare the silicon recess generated by continuous wave HBr/O2/Ar plasmas and synchronous pulsed HBr/O2/Ar plasmas. Thin SiO2 layers are exposed to continuous and pulsed HBr/O2/Ar plasmas, reproducing the overetch process conditions of a typical gate etch process. Using in situ ellipsometry and angle resolved X-ray photoelectron spectroscopy, the authors demonstrate that the oxidized layer which leads to silicon recess can be reduced from 4 to 0.8 nm by pulsing the plasma in synchronous mode.

The interaction of electromagnetic radiation with free electrons in the presence of an active medium has some appealing outcomes. Among them is particle acceleration by stimulated emission of radiation (PASER). In its framework, energy stored in an active medium (microscopic cavities) is transferred directly to an e -beam passing through. We have developed a two-dimensional analytic model for the evaluation of the energy exchange occurring as a train of electron microbunches traverses a dilute resonant medium. Efficient interaction occurs at resonance-namely, when the frequency of the train matches the resonance frequency of the medium. It is shown that the energy exchange is gamma independent for relativistic energies and it drops dramatically with an increase of the beam's radius. Based on this model, we have evaluated the relative change in the kinetic energy of a 0.1-nC 45-MeV macrobunch traversing an excited CO2 gas mixture-the former being modulated at the CO2 laser wavelength. Good agreement is found between the theoretical predictions and the results of the PASER experiment performed recently at Brookhaven National Laboratory.

Water uptake in porous low-k dielectrics has become a significant challenge for both back-end-of-line integration and circuit reliability. The influence of absorbed water on the mechanical properties of plasma-enhanced chemical-vapor-deposited organosilicate glasses (SiCOH) was investigated with nanoindentation. The roles of physisorbed (α-bonded) and chemisorbed (β-bonded) water were examined separately through annealing at different temperatures. Nanoindentation measurements were performed on dehydrated organosilicate glass during exposure to varying humidity conditions. The elastic modulus and hardness for as-deposited SiCOH are intimately linked to the nature and concentration of the absorbed water in the dielectric. Under mild-annealing conditions, the water-related film mechanical property changes were shown to be reversible. The mechanical properties of UV-cured SiCOH were also shown to depend on absorbed water, but to a lesser extent because UV curing depopulates the hydrophilic chemical groups in SiCOH. High-load indentation tests showed that in-diffusion of water in the film/substrate interface can degrade the hardness of SiCOH/Si film stacks significantly, while not significantly changing the elastic modulus.

We report the first experimental evidence for direct particle acceleration by stimulated emission of radiation. In the framework of this proof-of-principle experiment, a 45 MeV electron macrobunch was modulated by a high-power CO2 laser and then injected into an excited CO2 gas mixture. The emerging microbunches experienced a 0.15% relative change in the kinetic energy, in a less than 40 cm long interaction region. According to our experimental results, a fraction of these electrons have gained more than 200 keV each, implying that such an electron has undergone an order of magnitude of 2 x 10(6) collisions of the second kind.