Abstract: A substrate is provided with a patterned layer over a stack of one or more processing layers. The processing layers include at least one patterned layer and one etch target layer. CD trimming between the CD of the patterned layer and the CD of the etch target layer may be achieved after the pattern is transferred to the etch target layer. After the etch target layer is patterned, a plasma free gas phase etch process may be used to trim the CD of the etch target layer to finely tune the CD. In an alternate embodiment, plasma etch trim processes may be used in combination with the gas phase etch process. In such an embodiment, partial CD trimming may be achieved via the plasma etching of the various process layers and then additional CD trimming may be achieved by subjecting the etch target layer to the plasma free gas phase etch after the desired pattern has been formed in the etch target layer.

Abstract: A method for processing a substrate includes performing a first etch process to form a plurality of partial features in a dielectric layer disposed over the substrate; performing an irradiation process to irradiate the substrate with ultra-violet radiation having a wavelength between 100 nm and 200 nm; and after the irradiation process, performing a second etch process to form a plurality of features from the plurality of partial features.

Abstract: A substrate processing method is described for etching silicon carbide films for resist underlayer applications. The method includes providing a substrate containing a silicon carbide film thereon, and a photoresist layer defining a pattern over the silicon carbide film, plasma-exciting an etching gas containing a fluorocarbon-containing gas and an oxygen-containing gas, and exposing the substrate to the plasma-excited etching gas to transfer the pattern to the silicon carbide film, where at least a portion of a thickness of the photoresist layer survives the exposing. For example, the photoresist layer includes an EUV resist layer and the etching gas includes C4F8 gas, O2 gas, and Ar gas. In another example, the exposing includes exposing the substrate to a) a plasma-excited etching gas containing C4F8 gas, O2 gas, and Ar gas, and b) exposing the substrate to a plasma-excited Ar gas, where steps a) and b) are sequentially performed at least once.

Abstract: Systems and methods are provided herein for etch features on a substrate, while maintaining a near-unity critical dimension (CD) shrink ratio. The features etched may include, but are not limited to contacts, vias, etc. More specifically, the techniques described herein use a pulsed plasma to control the polymer build-up ratio between the major CD and minor CD of the feature, and thus, control the CD shrink ratio when etching features having substantially different major and minor dimensions. The CD shrink ratio is controlled by selecting or adjusting one or more operational parameters (e.g., duty cycle, RF power, etch chemistry, etc.) of the plasma etch process(es) to control the amount of polymer build-up at the major and minor dimensions of the feature.

Abstract: Methods are disclosed that provide improved via profile control by forming atomic layer deposition (ALD) liners to protect side walls of vias during subsequent etch processes. ALD liners can be used for BEOL etch processes as well as for full self-aligned via (FSAV) processes and/or other processes. For one embodiment, ALD liners are used as protection or sacrificial layers for vias to reduce damage during multilayer via or trench etch processes. The ALD liners can also be deposited at different points within process flows, for example, before or after removal of organic planarization layers. The use of ALD liners facilitates shrinking of via critical dimensions (CDs) while still controlling via profiles for various process applications including dual Damascene processes and FSAV processes. In addition, the use of ALD liners improves overall CD control for via or hole formation as well as device yield and reliability.

Abstract: In accordance with an embodiment, a method of plasma processing includes etching a refractory metal by flowing oxygen into a plasma processing chamber, intermittently flowing a passivation gas into the plasma processing chamber, and supplying power to sustain a plasma in the plasma processing chamber.

Abstract: Methods are provided herein for improving oxygen content control in a Metal-Insulator-Metal (MIM) stack of an RERAM cell, while also maintaining throughput. More specifically, a single chamber solution is provided herein for etching and encapsulating the MIM stack of an RERAM cell to control the oxygen content in the memory cell dielectric of the RERAM cell. According to one embodiment, a non-oxygen-containing dielectric encapsulation layer is deposited onto the MIM stack in-situ while the substrate remains within the processing chamber used to etch the MIM stack. By etching the MIM stack and depositing the encapsulation layer within the same processing chamber, the techniques described herein minimize the exposure of the memory cell dielectric to oxygen, while maintaining throughput.

Abstract: Embodiments are disclosed for processing microelectronic workpieces having patterned structures to improve mandrel pull from spacers for multi-color patterning. The disclosed embodiments form patterned structures on a substrate including mandrels, form spacers adjacent the mandrels that are recessed such that a height of the spacers is less than the height of the mandrels, form protective caps over the spacers while exposing top surfaces of the mandrels, and remove the mandrels to leave a spacer pattern with cap protection. The remaining spacer pattern can then be transferred to underlying layers in additional process steps. The recessing of the spacers and formation of the protective caps tends to reduce or eliminate spacer damage suffered by prior solutions during mandrel pull from spacers for multi-color patterning.

Abstract: Stacked structures, process steps, and methods for via and trench formation use a dielectric etch stop layer (ESL) to reduce or eliminate problems, such as process lag and chamfer erosion, that occur during conventional etch processes. A stacked structure is formed that includes a dielectric ESL within a dielectric layer, such as a low-dielectric (low-K) layer, to form a first low-K layer below the dielectric ESL and a second low-K dielectric layer above the dielectric ESL. When the stacked structure is subsequently etched to form trenches as well as vias through the stacked structure to underlying layers, the dielectric ESL reduces or eliminates RIE lag by ensuring that trenches (regardless of width) stop on the dielectric ESL. The dielectric ESL also acts as a protective layer to protect corners from chamfer erosion during via and trench etch processes.

Abstract: In certain embodiments, a method of forming a semiconductor device includes forming a patterned resist layer over a hard mask layer using an extreme ultraviolet (EUV) lithography process. The hard mask layer is disposed over a substrate. The method includes patterning the hard mask layer using the patterned resist layer as an etch mask. The method includes smoothing the hard mask layer by forming, using a first atomic layer etch step, a first layer by converting a first portion of the hard mask layer, and by removing, using a second atomic layer etch step, the first layer.

Abstract: This disclosure relates to a method for using a high volume manufacturing system for processing and measuring workpieces in a semiconductor processing sequence without leaving the system's controlled environment (e.g., sub-atmospheric pressure). The system includes an active interdiction control system to implement corrective processing within the system when a non-conformity is detected. The corrective processing method can include a remedial process sequence to correct the non-conformity or compensate for the non-conformity during subsequent process. The non-conformity may be associated with fabrication measurement data, process parameter data, and/or platform performance data.

Abstract: Methods and systems for selective deposition of conductive a cap for FAV features are described. In an embodiment, a method may include receiving a substrate having an interlayer dielectrics (ILD) layer, the ILD layer having a recess, the recess having a conductive layer formed therein, the conductive layer comprising a first conductive material. Additionally, such a method may include forming a cap within a region defined by the recess and in contact with a surface of the conductive layer, the cap comprising a second conductive material. The method may also include forming a conformal etch stop layer in contact with a surface of the cap and in contact with a region of the ILD layer. Further, the method may include selectively etching the etch stop layer using a plasma etch process, wherein the plasma etch process removes the etch stop layer selective to the second conductive material comprising the cap.

Abstract: A method of forming a device includes forming a patterned resist layer over a substrate using an extreme ultraviolet (EUV) lithography process. The method includes forming a mandrel in a plasma processing chamber by selectively depositing a mandrel material over the patterned resist layer, the mandrel including the patterned resist layer and the mandrel material.

Abstract: A method of forming a semiconductor device includes depositing a first layer over a substrate and patterning the first layer using an extreme ultraviolet (EUV) lithography process to form a patterned layer and expose portions of the substrate. The method includes, in a plasma processing chamber, generating a first plasma from a gas mixture including SiCl4 and one or more of argon, helium, nitrogen, and hydrogen. The method includes exposing the substrate to the first plasma to deposit a second layer including silicon over the patterned layer.

Abstract: A method of plasma etching includes receiving, by a plasma processing apparatus, a substrate into a processing chamber of the plasma processing apparatus. The substrate includes an etchable layer and a first mask layer overlying the etchable layer. The first mask layer includes a plurality of openings vertically aligned with exposed regions of the etchable layer. The method further includes forming, in the processing chamber, a protective layer over the first mask layer and the exposed regions and etching, in the processing chamber, the protective layer and the exposed regions to remove the protective layer and form recesses in the etchable layer.

Abstract: Split ash processes are disclosed to suppress damage to low-dielectric-constant (low-K) layers during via formation. For one embodiment, ash processes used to remove an organic layer, such as an organic planarization layer (OPL), associated with via formation are split into multiple ash process steps that are separated by intervening process steps. A first ash process is performed to remove a portion of an organic layer after vias have been partially opened to a low-K layer. Subsequently, after the vias are fully opened through the low-K layer, an additional ash process is performed to remove the remaining organic material. Although some damage may still occur on via sidewalls due to this split ash processing, the damage is significantly reduced as compared to prior solutions, and device performance is improved. Target critical dimension (CD) for vias and effective dielectric constants for the low-K layer are achieved.

Abstract: An atomic layer deposition (ALD) technique is used to deposit one or more layers on hard mask layers and the sidewalls of low-K dielectric trench as part of the trench etch process. The ALD layer(s) can prevent the hard mask from being eroded during various hard mask open processes. Further, the ALD layer(s) may be utilized to prevent the low-K dielectric sidewall from being laterally etched during the low-K dielectric trench etch. Hence, better control of the trench profile and better critical dimension control may be provided.

Abstract: A process is provided in which etched layer(s) are protected from residues or defects caused by or resulting from exposure to atmospheric conditions. Protection is provided through the formation of an encapsulation layer post etch. In one embodiment, the encapsulation is provided by a thin layer formed in an atomic layer deposition (ALD) process. The thin layer prevents the etched layer(s) from exposure to air. This encapsulation process may take place after the etch process thus allowing for substrates to be subsequently exposed to atmospheric conditions with little or no queue time constraints being needed for staging subsequent wet clean processing steps. In one embodiment, the encapsulation process may be performed with no vacuum break between the etch process and the encapsulation process. In one embodiment, the encapsulation film is compatible with subsequent wet process steps and can be removed during this wet process steps without adverse effects.

Abstract: This disclosure relates to a high volume manufacturing system for processing and measuring workpieces in a semiconductor processing sequence without leaving the system's controlled environment (e.g., sub-atmospheric pressure). The system includes an active interdiction control system to implement corrective processing within the system when a non-conformity is detected. The corrective processing can include a remedial process sequence to correct the non-conformity or compensate for the non-conformity during subsequent process. The non-conformity may be associated with fabrication measurement data, process parameter data, and/or platform performance data.

Abstract: A method of processing substrates, in one example microelectronic workpieces, is disclosed that includes forming a multi-layer metal hard mask (MHM) layer in which at least one lower layer of the multi-layer MHM is comprised of ruthenium (Ru). The Ru MHM layer may be an atomic layer deposition (ALD) Ru MHM layer formed over one or more underlying layers on a substrate. The ALD Ru MHM layer may be etched to provide a patterned ALD Ru MHM layer, and then the one or more underlying layers may be etched using, at least in part, the patterned ALD Ru MHM layer as a mask to protect portion of the one or more underlying layers. In one embodiment, at least one of the underlying layers is a hard mask layer.