Abstract: A method for making a semiconductor device comprises forming an electrical interconnect layer, forming a first dielectric layer over the interconnect layer, forming an opening in the first dielectric layer over a first electrical interconnect of the interconnect layer, forming an aluminum layer over the first dielectric layer, etching the aluminum layer to form an aluminum die pad, forming a second dielectric layer over the aluminum die pad and the first dielectric layer, and forming a conductive via through the first and second dielectric layers to contact a second electrical interconnect of the interconnect layer.

Abstract: A method for making a semiconductor device comprises forming an electrical interconnect layer, forming a first dielectric layer over the interconnect layer, forming an opening in the first dielectric layer over a first electrical interconnect of the interconnect layer, forming an aluminum layer over the first dielectric layer, etching the aluminum layer to form an aluminum die pad, forming a second dielectric layer over the aluminum die pad and the first dielectric layer, and forming a conductive via through the first and second dielectric layers to contact a second electrical interconnect of the interconnect layer.

Abstract: A method for making a semiconductor device comprises forming an electrical interconnect layer, forming a first dielectric layer over the interconnect layer, forming an opening in the first dielectric layer over a first electrical interconnect of the interconnect layer, forming an aluminum layer over the first dielectric layer, etching the aluminum layer to form an aluminum die pad, forming a second dielectric layer over the aluminum die pad and the first dielectric layer, and forming a conductive via through the first and second dielectric layers to contact a second electrical interconnect of the interconnect layer.

Abstract: A method for making a semiconductor device comprises forming an electrical interconnect layer, forming a first dielectric layer over the interconnect layer, forming an opening in the first dielectric layer over a first electrical interconnect of the interconnect layer, forming an aluminum layer over the first dielectric layer, etching the aluminum layer to form an aluminum die pad, forming a second dielectric layer over the aluminum die pad and the first dielectric layer, and forming a conductive via through the first and second dielectric layers to contact a second electrical interconnect of the interconnect layer.

Abstract: A method is provided for integrating a germanium photodetector with a CMOS circuit. The method comprises: forming first and second isolation regions in a silicon substrate; forming a gate electrode in the first isolation region; implanting source/drain extensions in the silicon substrate adjacent to the gate electrode; forming a first sidewall spacer on the gate electrode; implanting source/drain regions in the silicon substrate; removing the first sidewall spacer from the gate electrode; forming a first protective layer over the first and second isolation regions; removing a portion of the first protective layer to form an opening over the second isolation region; forming a semiconductor material comprising germanium in the opening; forming a second protective layer over the first and second isolation regions; selectively removing the first and second protective layers from the first isolation region; and forming contacts to the transistor and to the semiconductor material.

Abstract: A method for depositing a barrier or coating layer (34) in a semiconductor recessed structure (28) within a substrate (20) using a plasma process (62) that includes alternating depositing steps (64) and resputtering steps (66). The depositing step (64) deposits a barrier layer (34), including a thick bottom region (38) and a sidewall region (40) along the recessed structure (28) surface. The resputtering step (66) reduces the barrier layer (34) thickness in the bottom region (38) and increases the barrier layer (34) thickness in the otherwise thinly covered portions of the substrate sidewall region (40). Control of powers ranges supplied to the sputtering target (14) and the substrate (20) achieve the depositing and resputtering steps. The process applies also to other coating layers than barrier layers (34), providing a uniform sidewall coverage and thin bottom coverage, e.g., for permalloy deposition in MRAM devices and dual gate electrode formation in CMOS devices.

Abstract: A method for reducing the resistance within an opening, such as a via, in a dielectric (230) is described herein. A first barrier layer (250) is formed within the opening and the portion of the first barrier layer (250) at the bottom of the opening is removed, thereby exposing an underlying metal line (210). Deposited within the opening over the first barrier layer (250) and in contact with a conductor (210), a thin second barrier layer (260) forms a barrier between the conductor (210) and subsequently formed conductive material (270 and 280) within the opening. Because the second barrier layer (260) is thin, resistance is minimized between the conductor (210) and the conductive material (270 and 280). Additionally, if the opening is not aligned with the metal line (210), the second barrier layer (260) prevents the conductive material (270 and 280) from degrading an underlying dielectric (220) that may be present underneath the opening.

Abstract: A process for manufacturing semiconductors uses an enclosure (22) having an interior surface-that is intentionally-roughened by spraying quartz (44) onto the interior surface. The sprayed quartz (44) creates additional surface area for the purpose of trapping or capturing etched material in the enclosure during the process. The roughness of the interior surface is not significantly reduced during the semiconductor processing so that only chemical cleaning is required to maintain the interior surface for long-term use.

Abstract: A process for manufacturing semiconductors uses an enclosure (22) having an interior surface that is intentionally roughened by spraying quartz (44) onto the interior surface. The sprayed quartz (44) creates additional surface area for the purpose of trapping or capturing etched material in the enclosure during the process. The roughness of the interior surface is not significantly reduced during the semiconductor processing so that only chemical cleaning is required to maintain the interior surface for long-term use.

Abstract: In making inlaid structures in a semiconductor device, such as vias and trenches, a cavity is formed to expose an underlying metal layer. A degas step is then performed on the device which heats the device. If the device is then subjected to an RF sputter clean, some of the exposed metal is splattered onto the sidewall of the cavity. The problem that was discovered is that if the sidewall is too hot, this metal agglomerates. These agglomerations on the sidewall operate to block the continuous deposition of a seed layer. If the seed layer is not continuous, some portions of the seed layer may not receive the voltage necessary for the subsequent deposition by electroplating, leaving voids. To avoid these agglomerations, the device is actively cooled after the degas and before the sputtering commences so that agglomerations are not formed on the sidewall during the sputter clean.

Abstract: A method and an apparatus for forming a layer on a substrate are disclosed. In accordance with one embodiment, a substrate (901) is placed into a chamber (30) that includes a coil (16) and a shield (14) wherein the coil and the shield are electrically isolated by an isolation/support member (32) having a first surface (321) that is substantially contiguous with a surface of the coil and having a second surface (322) that is substantially contiguous with a surface of the shield. A layer (1002, 1102) is then deposited onto the substrate (901).

Abstract: A method for depositing a first metal layer such as tantalum or copper on a patterned semiconductor wafer using a metal sputtering tool that typically includes an electrically biased wafer chuck is disclosed. Initially, a first test wafer is placed on the wafer chuck and a first test layer of materials is deposited on the first test wafer. During the deposition of the first test layer on the first test wafer, the wafer receives the electrical bias at a first level. A second test wafer is then placed on the wafer chuck and a second test layer of material is deposited with the second wafer receiving a second level of electrical bias. The difference in thickness between the first layer and the second layer is then determined. If the difference in thickness is within a predetermined range, the metal sputtering chamber is qualified to deposit a production layer on a production semiconductor wafer.

Abstract: A method for forming an improved copper inlaid interconnect (FIG. 11) begins by performing an RF preclean operation (408) on the inlaid structure in a chamber (10). The RF preclean rounds corners (210a and 206a) of the structure to reduce voiding and improve step coverage while not significantly removing copper atoms from the underlying exposed copper interconnects surfaces (202a). A tantalum barrier (220) is then deposited where one portion of the tantalum barrier is more tensile than another portion of the tantalum barrier. After formation of the barrier layer (220), a copper seed layer (222) is formed over a top of the barrier layer. The copper layer is formed while clamping the wafer with an improved clamp (85) which reduces copper peeling and contamination at wafer edges. Copper electroplating and chemical mechanical polishing (CMP) processes are then used to complete the copper interconnect structure.

Abstract: A method for forming an improved copper inlaid interconnect (FIG. 11) begins by performing an RF preclean operation (408) on the inlaid structure in a chamber (10). The RF preclean rounds corners (210a and 206a) of the structure to reduce voiding and improve step coverage while not significantly removing copper atoms from the underlying exposed copper interconnects surfaces (202a). A tantalum barrier (220) is then deposited where one portion of the tantalum barrier is more tensile than another portion of the tantalum barrier. After formation of the barrier layer (220), a copper seed layer (222) is formed over a top of the barrier layer. The copper layer is formed while clamping the wafer with an improved clamp (85) which reduces copper peeling and contamination at wafer edges. Copper electroplating and chemical mechanical polishing (CMP) processes are then used to complete the copper interconnect structure.

Abstract: The formation of an adhesion/interlayer region (410) of a semiconductor substrate device (404) before barrier layer (412) deposition provides improved adhesion of the barrier layer (412) to the underlying dielectric (404) and increases strength to the next interconnect layer without altering the function of the barrier layer (412) to limit Cu diffusion into the dielectric substrate (404). The adhesion/interlayer region (410) is formed in an inlaid structure (400, 500) of a semiconductor wafer. The inlaid structure (400, 500) is connected to upper or lower metal layers through vias in the dielectric layer (404) to a copper layer. The adhesion/interlayer region is formed by flowing a treating gas in a glow discharge process of the dielectric substrate in a chamber either attached or separated from the barrier deposition chamber (300). The barrier layer (412) and the adhesion/interlayer region (410) can be formed in this inlaid structure (400, 500) of a semiconductor wafer.

Abstract: An interconnect (60) is formed overlying a substrate (10). In one embodiment, an adhesion/barrier layer (81), a copper-alloy seed layer (42), and a copper film (43) are deposited overlying the substrate (10), and the substrate (10) is annealed. In an alternate embodiment, a copper film is deposited over the substrate, and the copper film is annealed. In yet another embodiment, an adhesion/barrier layer (81), a seed layer (82), a conductive film (83), and a copper-alloy capping film (84) are deposited over the substrate (10) to form an interconnect (92). The deposition and annealing steps can be performed on a common processing platform.

Abstract: A method for insitu performing a cleaning operation along with a physical sputtering operation begins by placing a wafer (26) into a chamber (12). A plasma (30) is generated within the chamber (12) using an inert, noble, or reducing gas. The gas is ionized to form ions (32) within the plasma (30). Power is provided to various components (16, 22, and 24) within the chamber (12) to ensure that the ions (32) are accelerated towards the wafer (26) during first stages of wafer processing. This acceleration of the ions (32) towards the wafer (26) will clean a surface of the wafer (26). Following this cleaning operation, power supplied within the chamber (12) is altered to accelerate the ions (32) into a reverse direction so that the ions (32) impact a sputter target (20). Due to ionic bombardment of the target (20), a material is sputtered onto a clean surface of the wafer (26) in an insitu manner.

Abstract: A method and an apparatus for forming a layer on a substrate are disclosed. In accordance with one embodiment, a substrate (901) is placed into a chamber (30) that includes a coil (16) and a shield (14) wherein the coil and the shield are electrically isolated by an isolation/support member (32) having a first surface (321) that is substantially contiguous with a surface of the coil and having a second surface (322) that is substantially contiguous with a surface of the shield. A layer (1002, 1102) is then deposited onto the substrate (901).

Abstract: A method for forming an improved copper barrier layer begins by providing a silicon-containing layer (10). A physical vapor deposition process is then used to form a thin tantalum nitride amorphous layer (12). A thin amorphous titanium nitride layer (14) is then deposited over the amorphous tantalum nitride layer. A collective thickness of the tantalum nitride and titanium nitride layers 12 and 14 is roughly 400 angstroms or less. A copper material 16 is then deposited on top of the amorphous titanium nitride wherein the composite tantalum nitride layer 12 and titanium nitride layer 14 effectively prevents copper from diffusion from the layer 16 to the layer 10.

Abstract: A metal-semiconductor layer (26) is formed over an insulating layer (20) such that the metal-semiconductor layer (26) is graded to have varying amounts of the semiconductor and metal throughout the layer. In one embodiment, the metal-semiconductor layer (26) has relatively higher silicon content near the layer's lower and upper surfaces. At the midpoint, the layer is close to stoichiometric tungsten silicide. In another embodiment, a metal-semiconductor-nitrogen layer is formed having nitrogen nearer the lower surface and essentially no nitrogen near the upper surface. The layer (26) can be formed using chemical vapor deposition or sputtering.