Abstract: A copper interconnect having a transition metal-nitride barrier (106) with a thin metal-silicon-nitride cap (108). A transition metal-nitride barrier (106) is formed over the structure. Then the barrier (106) is annealed in a Si-containing ambient to form a silicon-rich capping layer (108) at the surface of the barrier (106). The copper (110) is then deposited over the silicon-rich capping layer (108) with good adhesion.

Abstract: A dual damascene process. After the via etch, a via protect layer (114) is deposited in the via (112). The via protect layer (114) comprises a material that has a dry etch rate at least equal to that of the IMD (108) and a wet etch rate that is approximately 100 times that of the IMD (108) or greater. Exemplary materials include PSG, BPSG, and HSQ. The trench pattern (120) is formed and both the via protect layer (114) and IMD (108) are etched. The remaining portions of the via protect layer (114) are then removed prior to forming the metal layer (122).

Abstract: A method of isolating an exposed conductive surface. An aluminum layer (130) is selectively formed over the exposed conductive (106) surface (e.g., Cu) but not over the surrounding dielectric (110) surface using a thermal CVD process. The aluminum layer (130) is then oxidized to form a thin isolating aluminum-oxide (108) over only the conductive surface. The isolating aluminum-oxide provides a barrier for the Cu while taking up minimal space and reducing the effective dielectric constant.

Abstract: A polysilicon layer of a gate structure is covered by a film that blocks introduction of implanted dopants into the polysilicon layer, while allowing implantation into the source and drain. The implant blocking film is removed before metal deposition for the salicide process.

Abstract: A method for fabricating a metal conductor in a semiconductor device includes forming a trench in a dielectric layer of the semiconductor device. The method also includes depositing a first conducting material within the trench to form a continuous liner layer within the trench. The liner layer is formed at a first predetermined temperature. The method further includes filling a remaining portion of the trench over the liner layer with a second conducting material at a second predetermined temperature. The second predetermined temperature is greater than the first predetermined temperature.

Abstract: An embodiment of the instant invention is a method of making a transistor having a silicided gate structure insulatively disposed over a semiconductor substrate, the method comprising the steps of: forming a conductive structure insulatively disposed over the semiconductor substrate (step 302 of FIG. 3); introducing a silicide enhancing substance into the conductive structure (step 304 of FIG. 3); amorphizing a portion of the conductive structure; forming a metal layer on the conductive structure (step 310 of FIG. 3); and wherein the metal layer interacts with the silicide enhancing substance in the amorphized portion of the conductive structure so as to form a lower resistivity silicide on the conductive structure. The conductive structure is, preferably, comprised of: doped polysilicon, undoped polysilicon, epitaxial silicon, or any combination thereof. Preferably, the silicide enhancing substance is comprised of: molybdenum, Co, W, Ta, Nb, Ru, Cr, any refractory metal, and any combination thereof.

Abstract: An embodiment of the instant invention is a method of making a transistor having a silicided gate structure insulatively disposed over a semiconductor substrate, the method comprising the steps of: forming a conductive structure insulatively disposed over the semiconductor substrate (step 302 of FIG. 3); introducing a silicide enhancing substance into the conductive structure (step 304 of FIG. 3); amorphizing a portion of the conductive structure; forming a metal layer on the conductive structure (step 310 of FIG. 3); and wherein the metal layer interacts with the silicide enhancing substance in the amorphized portion of the conductive structure so as to form a lower resistivity silicide on the conductive structure. The conductive structure is, preferably, comprised of: doped polysilicon, undoped polysilicon, epitaxial silicon, or any combination thereof. Preferably, the silicide enhancing substance is comprised of: molybdenum, Co, W, Ta, Nb, Ru, Cr, any refractory metal, and any combination thereof.

Abstract: A dual inlaid interconnect fabrication method using a temporary filler in a via during trench etch and removal of the filler after trench etch. This provides via bottom protection during trench etch.

Abstract: A method for forming a metal interconnect having a self-aligned transition metal-nitride barrier (124). After the metal interconnect lines (118) are formed, a transition metal (120) is deposited over the surface of the metal interconnect lines (118) and reacted in to form a metal-compound (122). The metal-compound (122) is then annealed in a nitrogen ambient to form a barrier layer (114) at the surface of the metal interconnect lines (118).

Abstract: A method of making connection between an aluminum or aluminum based material and tungsten. The method includes providing an underlying region containing a layer of tungsten thereover. The underlying region is preferably a layer of titanium over which is a layer of titanium nitride. The layer of tungsten is etched back to the underlying region while exposed tungsten is retained over a portion of the underlying region. The underlying region also may contain a via therein which contains the exposed tungsten. An nitrogen-containing plasma, preferably elemental nitrogen, is then applied to the exposed tungsten and exposed underlying region and a layer of a barrier material is formed by reaction of the nitrogen in the plasma and the tungsten over the exposed tungsten. A further barrier layer, preferably titanium nitride, is optionally then applied followed by a layer of aluminum over the exposed surface, the barrier layer isolating the layer of aluminum from the tungsten.

Abstract: A new liner structure and method to incorporate this liner into process flows in order to lower the processing temperature of aluminum extrusion or reflow cavity filling. The structures produced by this innovative method are particularly useful for advanced sub-quarter micron multi-level interconnect applications.

Abstract: A method for forming a ultra-shallow junction region (104). A silicon film (single crystalline, polycrystalline or amorphous) is deposited on the substrate (100) to form an elevated S/D (106). A metal film is deposited over the silicon film and reacted with the silicon film to form a silicide film (108). The silicon film is preferably completely consumed by the silicide film formation. An implant is performed to implant the desired dopant either into the metal film prior to silicide formation or into the silicide film after silicide formation. A high temperature anneal is used to drive the dopant out of the silicide film to form the junction regions (104) having a depth in the substrate (100) less than 200 Å. This high temperature anneal may be one of the anneals that are part of the silicide process or it may be an additional process step.

Abstract: An integrated circuit structure including copper metallization (20, 32, 42), and a method of fabricating the same are disclosed. The structure includes a doped region (7) of a silicon substrate (9), which is typically clad with a metal silicide film (12) formed by way of direct react silicidation. At contact locations (CT) at which the copper metallization (20, 32, 42) is to make contact to the doped region (7), a chemically-densified barrier layer (16, 30, 38) provides a diffusion barrier to the overlying copper metallization (20, 32, 42). The chemically-densified barrier layer (16, 30, 38) is formed by an anneal of the structure to react impurities (14, 28, 36) with the underlying refractory-metal-based film (12, 34); the impurities are introduced by way of wet chemistry, plasma bombardment, or from the ambient in which the structure is annealed.

Abstract: Cavities such as vias and contacts formed in semiconductor devices are filled in a multi-stage process to provide low resistance electrical connections. A liner is first deposited into the cavity at a relatively low power and deposition rate to enhance "wetting" of a subsequently deposited fill material. The fill material is deposited at a comparatively greater power and deposition rate to close the mouth of the cavity, after which the fill material is extruded at high pressure into the cavity to substantially fill the cavity. Relatively low processing temperatures and high pressures are utilized to allow for the use of lower dielectric constant dielectrics, which are thermally unstable at conventional processing temperatures.

Abstract: An integrated circuit fabrication method for filling a high-aspect-ratio via with a metallization layer wherein there is provided a dielectric layer having a via therein. A wetting layer is deposited over the dielectric layer and within the via and the via sidewalls, the wetting layer being of a material which lowers the melting temperature of the metallization when combined with the metallization. The metallization layer is deposited over the wetting layer and the via but not completely filling the via with the metallization. The wetting agent with metallization thereon are heated to a temperature below the melting temperature of the metallization, the temperature being sufficient to cause the wetting layer to combine with the metallization, lower the melting temperature of the metallization to the temperature or below the heating temperature to cause the metallization to flow and fill the via.

Abstract: A process for producing conformal and stable TiN+Al films, which provides flexibility in selecting the chemical composition and layering. In this new process, porous TiCN is first deposited, and then Al is incorporated by exposing the porous film to CVD aluminum conditions at low temperatures.

Abstract: Method of fabricating a narrow linewidth transistor having a low sheet resistance. The transistor may be fabricated in a surface of a semiconductor layer (12). A gate body (14) may be formed separated from an outer surface (16) of the semiconductor layer (12) by a gate insulator (18). The gate body (14) may have an inner surface (20) proximate to the semiconductor layer (12) and an opposite outer surface (22). An insulator layer (30) may be deposited outwardly of the semiconductor layer (12) and the gate body (14). The insulator layer (30) may be anisotropically etched to form side walls (32) adjacent to the gate body (14). The anisotropic etch may cause a residual layer of contaminants (34) to form on the outer surface (16) of the semiconductor layer (12) and on the outer surface (22) of the gate body (14). A protective layer (50) may be deposited outwardly of the residual layer of contaminants (34). Dopants may be implanted into the semiconductor layer (12) proximate to the side walls (32).

Abstract: A method is provided for forming thin diffusion barriers in a semiconductor device (10). In one embodiment of the invention, a metal precursor gas is introduced to a surface of a dielectric layer. A predetermined amount of heat is then applied to the metal precursor gas and the dielectric layer. The heat causes the metal precursor gas to react with the dielectric layer, thereby forming a uniform, relatively thin diffusion barrier on the surface of the dielectric layer. In another embodiment of the invention, a metal precursor gas is introduced to a surface of a metal conductor. A predetermined amount of heat can then be applied to the metal precursor gas and the metal conductor, which creates a reaction between the gas and the conductor, and thereby produces a thin diffusion barrier on the surface of the metal conductor.

Abstract: A method to improve the texture of titanium and aluminum to reduce electromigration by controlling the deposition conditions and the texture of the substrates. Aluminum films can develop strong <111> texture, when titanium is used underneath aluminum. However, to prevent the interaction between aluminum and titanium, a layer of TiN or other barrier is necessary. Fortunately, TiN has a similar atom arrangement on the <111> plane as that of aluminum <111> and titanium <002>. Therefore, by controlling the orientation of titanium using a pre-sputter argon etch and low titanium deposition temperature, the texture of titanium can be transferred to TiN, and subsequently to aluminum.

Abstract: A method is provided for improving the texture of a metal interconnect (32) in a semiconductor device (10). A first layer of titanium (24), a layer of titanium nitride (26), a second layer of titanium (28), and a metal film (30) are sequentially formed over an oxide layer (12). The second titanium layer (28) is preferably out 10-20 nm thick. Because the metal film (30) is formed over the second titanium layer (28), any metal interconnect (32) that is formed as a part of the metal film (30) has a strong (111) crystalline orientation. Furthermore, because the second titanium layer (28) is relatively thin, the metal film (30) and metal interconnect (32) are not completely transformed into a metal compound having a high electrical resistance.