Abstract: A method of manufacturing a MOSFET semiconductor device comprises providing a gate electrode having first and second opposing sidewalls over a substrate having source/drain regions; providing a gate oxide between the gate electrode and the substrate; forming first and second sidewall spacers respectively disposed adjacent the first and second sidewalls; pre-cleaning the sidewall spacers; forming a nickel layer; and forming nickel silicide layers disposed on the source/drain regions and the gate electrode. The nickel silicide layers are formed during a rapid thermal anneal at temperatures from about 380 to 600° C. The pre-clean uses a hydrogen reactive system in an atmosphere comprising hydrogen and helium. Also, the pre-clean and the formation of the nickel layer are sequentially performed in a single physical vapor deposition chamber system.

Abstract: Bridging between nickel silicide layers on a gate electrode and source/drain regions along silicon nitride sidewall spacers is prevented by treating the exposed surfaces of the silicon nitride sidewall spacers with a nitrogen oxide plasma to create a surface region having reduced free silicon. Embodiments include treating the silicon nitride sidewall spacers with a nitrogen plasma to reduce the refractive index of the surface region to less than about 1.95.

Abstract: Bridging between nickel suicide layers on a gate electrode and source/drain regions along silicon nitride sidewall spacers is prevented by treating the exposed surfaces of the silicon nitride sidewall spacers with a nitrogen plasma to create a surface region having reduced free silicon. Embodiments include treating the silicon nitride sidewall spacers with a nitrogen plasma to reduce the refractive index of the surface region to less than about 1.95.

Abstract: A manufacturing method, and an integrated circuit resulting therefrom, has a substrate and a semiconductor device thereon. A stop layer over the substrate has a first dielectric layer formed thereon having an opening into which a first conformal barrier is formed. A first conformal barrier liner is formed in the opening, processed, and treated to improve adhesion. Portions of the first conformal barrier liner on the sidewalls act as a barrier to diffusion of conductor core material to the first dielectric layer. A conductor material is formed in the opening over the vertical portions of the first conformal barrier liner and the first stop layer.

Abstract: A structure and method for determining barrier layer integrity for multi-level copper metallization structures in integrated circuit manufacturing. Novel testing structures prevent any conducting residues of the copper CMP from diffusing into the dielectric layer. Barrier layer integrity is tested by performing CV or IV measurements between the copper lines and the silicon wafer.

Abstract: A method (M) of determining the effectiveness of a deposited thin conformal barrier layer (30) by forming a test specimen and measuring the copper (Cu) penetration from a metallization layer (40) through the barrier layer (30) (e.g., refractory metals, their nitrides, their carbides, or their other compounds), through a thin insulating dielectric layer (20) (e.g., SiO2), and into a semiconductor (10) substrate (e.g., Si), wherein the interaction between the migrating metal ions and the semiconductor ions are detected/monitored, and wherein the detection/monitoring comprises (1) stripping at least a portion of the insulating dielectric layer (20) and the barrier layer (30) and (2) examining the semiconductor substrate (10) surface of the test specimen, thereby improving interconnect reliability, enhancing electromigration resistance, improving corrosion resistance, reducing copper diffusion, and a test specimen device thereby formed.

Abstract: A self-aligned silicide process that can accommodate a low thermal budget and form silicide regions of small dimensions in a controlled reaction. In a first temperature treatment, nickel metal or nickel alloy is reacted with a silicon material to form at least one high resistance nickel silicide region. Unreacted nickel is removed. A dielectric layer is then deposited over a high resistance nickel silicide regions. In a second temperature treatment, the at least one high resistance nickel silicide region and dielectric layer are reacted at a prescribed temperature to form at least one low resistance silicide region and process the dielectric layer. Bridging between regions is avoided by the two-step process as silicide growth is controlled, and unreacted nickel between silicide regions is removed after the first temperature treatment. The processing of the high resistance nickel silicide regions and the dielectric layer are conveniently combined into a single temperature treatment.

Abstract: An integrated circuit test system and method therefor is provided having a semiconductor substrate with an electrical ground and a source of electrical potential. A dielectric layer with first and second openings is formed on the semiconductor substrate. First and second barrier layers are deposited on the dielectric layer to line the openings. A first conductor core is deposited over the first barrier layer to fill the first opening and is connected to a source of electrical potential. A second conductor core is deposited over the second barrier layer to fill the second opening and is connected to the electrical ground. A current measuring device is provided to measure leakage current flow between the first and second conductor cores.

Abstract: An integrated circuit and manufacturing method therefor is provided having a semiconductor substrate with a semiconductor device and a device dielectric layer formed on the semiconductor substrate. A channel dielectric layer on the device dielectric layer has a channel opening and a conductor core filling the channel opening. A via stop layer is formed over the channel dielectric layer to have a hydrogen concentration below 15 atomic % and a via dielectric layer is formed over the via stop layer and has a via opening. A second channel dielectric layer over the via dielectric layer has a second channel opening. A second conductor core, filling the second channel opening and the via opening, is connected to the semiconductor device.

Abstract: An integrated circuit and manufacturing method therefor is provided having a semiconductor substrate with a semiconductor device. A first conductor core is connected to the semiconductor device. A low dielectric constant dielectric layer is formed over the semiconductor substrate and has an opening formed therein. A first barrier layer is deposited over the first conductor core. A second barrier layer is deposited to line the low dielectric constant dielectric layer and the first barrier layer. A third barrier layer is deposited to line the second barrier layer. A second conductor core is deposited to fill the opening over the third barrier layer.

Abstract: A method of manufacturing a MOSFET semiconductor device comprises providing a gate electrode having first and second opposing sidewalls over a substrate having source/drain regions; providing a gate oxide between the gate electrode and the substrate; forming first and second sidewall spacers respectively disposed adjacent the first and second sidewalls; implanting nitrogen into the sidewall spacers; forming a nickel layer; and forming nickel suicide layers disposed on the source/drain regions and the gate electrode. The nickel silicide layers are formed during a rapid thermal anneal at temperatures from about 380 to 600° C. The nitrogen implantation process is a plasma treating in a plasma-enhanced chemical vapor deposition chamber, and the nickel deposition is performed in a physical deposition chamber. Also, the implantation process and the formation of the nickel layer are sequentially performed without removal from a non-oxidizing atmosphere.

Abstract: A method of manufacturing a semiconductor device includes providing a gate electrode having first and second opposing sidewalls over a substrate having source/drain regions; forming first and second sidewall spacers respectively disposed adjacent the first and second sidewalls; and forming first and second nickel silicide layer respectively disposed on the source/drain regions and the gate electrode. The nickel silicide layer over the gate electrode can be thicker than the nickel silicide layer over the source/drain regions. A semiconductor device formed from the method is also disclosed.

Abstract: A method of forming a fully silicidized gate of a semiconductor device includes forming silicide in active regions and a portion of a gate. A shield layer is blanket deposited over the device. The top surface of the gate electrode is then exposed. A refractory metal layer is deposited and annealing is performed to cause the metal to react with the gate and fully silicidize the gate, with the shield layer protecting the active regions of the device from further silicidization to thereby prevent spiking and current leakage in the active regions.

Abstract: A method for forming a metal interconnect structure provides a conformal layer of barrier material, such as a nitride, within a patterned opening in a dielectric layer. The barrier material is deposited after the opening is etched to the dielectric layer, stopping on a diffusion barrier. A first layer of a metal barrier material, such as tantalum, is conformally deposited on the barrier material. A directional etch is performed that removes horizontal nitride and tantalum, leaving the nitride and tantalum on the sidewalls of the patterned opening. The barrier material prevents contamination of the dielectric layer from conductive material, such as copper, during the etching of the diffusion barrier overlying the conductive material, and during subsequent sputter etch cleaning. A thin, second metal layer is conformally deposited and forms a suitable barrier on the sidewalls of the opening, while providing low contact resistance between the second metal layer and the underlying substrate.

Abstract: Semiconductor devices having fully metal silicided gate electrodes, and methods for making the same, are disclosed. The devices have shallow S/D extensions with depths of less than about 500 Å. The methods for making the subject semiconductor devices employ diffusion of dopant from metal suicides to form shallow S/D extensions, followed by high energy implantation and activation, and metal silicidation to form S/D junctions having metal silicide connect regions and a fully metal silicided electrode.

Abstract: Bridging between nickel silicide layers on a gate electrode and source/drain regions along silicon nitride sidewall spacers is prevented by forming a relatively thick silicon oxide liner on the side surfaces of the gate electrode and adjacent surface of the semiconductor substrate before forming the silicon nitride sidewall spacers thereon. Embodiments include forming a silicon dioxide liner at a thickness of about 200 Å to about 600 Å prior to forming the silicon nitride sidewall spacers thereon.

Abstract: Cu or a Cu alloy is deposited to partially fill openings in a dielectric layer and then annealed. Incomplete filling leaves room in the openings to accommodate a volume change associated with grain growth and, hence, prevents the generation of voids. The openings are then completely filled, annealed a second time and then planarized, as by CMP. Embodiments include partially filling about 70% to about 90% of the volume of the trenches and then annealing before completely filling the trenches.

Abstract: Bridging between nickel silicide layers on a gate electrode and source/drain regions along silicon nitride sidewall spacers is prevented by employing composite silicon nitride sidewall spacers comprising an outer layer having reduced free silicon. Embodiments include forming composite silicon nitride sidewall spacers comprising an inner silicon nitride layer, having a refractive index of about 1.95 to about 2.05 and a thickness of about 450 Å to about 550 Å, on the side surfaces of the gate electrode and an outer silicon nitride layer, having a refractive index to less than about 1.95 and a thickness of about 350 Å to about 450 Å.

Abstract: Nickel silicidation of a gate electrode is controlled using a cobalt barrier layer. Embodiments include forming a gate electrode structure comprising a lower polycrystalline silicon layer, a layer of cobalt thereon and an upper polycrystalline silicon layer on the cobalt layer, depositing a layer of nickel and silicidizing, whereby the upper polycrystalline silicon layer is converted to nickel suicide and a cobalt silicide barrier layer is formed preventing nickel from reacting with the lower polycrystalline silicon layer.

Abstract: An integrated circuit and a method for manufacture thereof are provided having a semiconductor substrate with a semiconductor device. A device dielectric layer is formed on the semiconductor substrate. An opening is formed in the dielectric layer. A barrier layer with an alloying element is deposited to line the opening in the dielectric layer. A conductor core is deposited on the barrier layer to fill the opening and connect to the semiconductor device. The conductor core is annealed causing migration of the alloy element into the conductor core.