Title: Chemistry of Epitaxy
1Chemistry of Epitaxy
2- Epitaxy is an interface between a thin film and a
substrate - The term epitaxy describes an ordered crystalline
growth on a monocrystalline substrate - Epitaxial films may be grown from gaseous or
liquid precursors - Because the substrate acts as a seed crystal, the
deposited film takes on a lattice structure and
orientation identical to those of the substrate
3- Epitaxy is different from other thin film
deposition methods which deposit polycrystalline
or amorphous films, even on single - crystal
substrates - If a film is deposited on a substrate of the same
composition, the process is called homoepitaxy - Otherwise it is called heteroepitaxy
- Homoepitaxy is a kind of epitaxy performed with
only one material in which a crystalline film is
grown on a substrate or film of the same material
- This technology is applied to growing a more
purified film than the substrate and fabricating
layers with different doping levels
4- Heteroepitaxy is a kind of epitaxy performed with
materials that are different from each other in
which a crystalline film grows on a crystalline
substrate or film of another material - This technology is often applied to growing
crystalline films of materials of which single
crystals cannot be obtained and to fabricating
integrated crystalline layers of different
materials - Examples include gallium nitride (GaN) on
sapphire or aluminum gallium indium phosphide
(AlGaInP) on gallium arsenide (GaAs) - Heterotopotaxy is a process similar to
heteroepitaxy except for the fact that thin film
growth is not limited to two dimensional growth - In this process, the substrate is similar only in
structure to the thin film material
5- Epitaxy is used in silicon - based manufacturing
processes for BJTs and modern CMOS, but it is
particularly important for compound
semiconductors such as gallium arsenide - Manufacturing issues include control of the
amount and uniformity of the deposition's
resistivity and thickness, the cleanliness and
purity of the surface and the chamber atmosphere,
the prevention of the typically much more highly
doped substrate wafer's diffusion of dopant to
the new layers, imperfections of the growth
process, and protecting the surfaces during the
manufacture and handling
6- Applications of Epitaxy
- Epitaxy has applications in nanotechnology and in
semiconductor fabrication. - Epitaxy is the only affordable method of high
crystalline quality growth for many semiconductor
materials, including technologically important
materials as silicon -germanium, gallium nitride,
gallium arsenide and indium phosphide - Epitaxy is also used to grow layers of pre -
doped silicon on the polished sides of silicon
wafers, before they are processed into
semiconductor devices.
7- Epitaxy is one of the most vital processes in
semiconductor device manufacturing - This is especially true in nanotechnology, as it
provides the means of growing very thin films in
a controlled way to achieve the necessary
accuracy, purity, and orientation of the film
- Chemistry plays an important role in the process
of epitaxial layer growth - The constituents of the film are often presented
to the substrate in the form of compounds with
other elements - They must be extracted from these compounds and
react with the substrate and possibly other
constituents to form the epitaxial layer
8- There are many approaches to growing epitaxial
films - Vapor Phase Epitaxy (VPE)
- Liquid Phase Epitaxy (LPE)
- Metallorganic Chemical Vapor Deposition (MOCVD)
- Molecular Beam Epitaxy (MBE)
- Atomic Layer Epitaxy (ALE)
- Several of these methods are based on Chemical
Vapor Deposition (CVD)
9Chemical Vapor Deposition (CVD)
- CVD is used to produce high - purity, high
-performance solid materials, usually in the form
of a thin film on a substrate - In a typical CVD process, the wafer (substrate)
is exposed to one or more volatile precursors,
which react and/or decompose on the substrate
surface to produce the desired deposit - Frequently, volatile byproducts are also
produced, which are removed by gas flow through
the reaction chamber
10- Microfabrication processes widely use CVD to
deposit materials in various forms, including
monocrystalline, polycrystalline, amorphous, and
epitaxial - These materials include silicon, carbon fiber,
carbon nanofibers, filaments, carbon nanotubes,
SiO2, silicon-germanium, tungsten, silicon
carbide, silicon nitride , titanium nitride, and
various high - k dielectrics - The CVD process is also used to produce synthetic
diamonds
11- Types of chemical vapor deposition
- A number of forms of CVD are in wide use and are
frequently referenced in the literature - These processes differ in the means by which
chemical reactions are initiated (e.g.,
activation process) and process conditions
12- These processes can be classified by operating
pressure - Atmospheric pressure CVD (APCVD) - CVD processes
at atmospheric pressure - Low-pressure CVD (LPCVD) - CVD processes at
subatmospheric pressures - Reduced pressures tend to reduce unwanted
gas-phase reactions and improve film uniformity
across the wafer - Most modern CVD process are either LPCVD or
UHVCVD - Ultrahigh vacuum CVD (UHVCVD) - CVD processes at
a very low pressure, typically below 10 -6 Pa (
10 -8 torr)
13- Classified by physical characteristics of vapor
- Aerosol assisted CVD (AACVD) - A CVD process in
which the precursors are transported to the
substrate by means of a liquid/gas aerosol, which
can be generated ultrasonically. - This technique is suitable for use with
nonvolatile precursors - Direct liquid injection CVD (DLICVD) - A CVD
process in which the precursors are in liquid
form (liquid or solid dissolved in a convenient
solvent) - Liquid solutions are injected in a vaporization
chamber towards injectors (typically car
injectors). - The precursor vapors are then transported to the
substrate as in classical CVD process - This technique is suitable for use on liquid or
solid precursors - High growth rates can be reached using this
technique
14- Microwave plasma-assisted CVD (MPCVD)
- Plasma-Enhanced CVD (PECVD) - CVD processes that
utilize a plasma to enhance chemical reaction
rates of the precursors - PECVD processing allows deposition at lower
temperatures, which is often critical in the
manufacture of semiconductors - Remote plasma-enhanced CVD (RPECVD) - Similar to
PECVD except that the wafer substrate is not
directly in the plasma discharge region - Removing the wafer from the plasma region allows
processing temperatures down to room temperature - Atomic layer CVD (ALCVD) Deposits successive
layers of different substances to produce
layered, crystalline films - Hot wire CVD (HWCVD) - Also known as Catalytic
CVD (Cat-CVD) or hot filament CVD (HFCVD) - Uses a hot filament to chemically decompose the
source gases
15- Metallorganic chemical vapor deposition (MOCVD) -
CVD processes based on metallorganic precursors - Hybrid Physical-Chemical Vapor Deposition (HPCVD)
- Vapor deposition processes that involve both
chemical decomposition of precursor gas and
vaporization of solid a source - Rapid thermal CVD (RTCVD) - CVD processes that
use heating lamps or other methods to rapidly
heat the wafer substrate - Heating only the substrate rather than the gas or
chamber walls helps reduce unwanted gas phase
reactions that can lead to particle formation - Vapor phase epitaxy (VPE)
16- Polysilicon
- Polycrystalline silicon is widely used as the
gate oxide in MOSFETs - Polycrystalline silicon is deposited from silane
(SiH4), using the following reaction -
- This reaction is usually performed in LPCVD
systems, with either pure silane feedstock, or a
solution of silane with 70-80 nitrogen - Temperatures between 600 and 650 C and pressures
between 25 and150 Pa yield a growth rate between
10 and 20 nm per minute. An alternative process
uses a hydrogen - based solution - The hydrogen reduces the growth rate, but the
temperature is raised to 850 or even 1050 C to
compensate
17- Polysilicon may be grown directly with doping, if
gases such as phosphine, arsine or diborane are
added to the CVD chamber - Diborane increases the growth rate, but arsine
and phosphine decrease it
18TEOS
- TEOS is a material commonly used to grow silicon
dioxide layers on semiconductors - It stands for Tetra - Ethyl - Ortho - Silicate,
or equivalently tetra - ethoxy - silane
- TEOS slowly hydrolyzes into silicon dioxide and
ethanol when in contact with ambient moisture
19- The key to understanding the difference between
TEOS and silane is to note that in TEOS the
silicon atom is already oxidized - The conversion of TEOS to silicon dioxide is
essentially a rearrangement rather than an
oxidation reaction, with much reduced changes in
free enthalpy and free energy
20- The basic overall reaction for the deposition of
silicon dioxide requires the removal of two
oxygen atoms
21- While gas phase reactions can occur, particularly
at the high end of the temperature range,
deposition is probably the result of TEOS surface
reactions - TEOS chemisorbs onto silanol groups (Si-OH) at
the surface, as well as strained surface bonds
22- TEOS will not adsorb onto the resulting
alkyl-covered surface, so deposition is probably
limited by removal of the surface alkyl groups - These groups can undergo elimination reactions
with neighboring molecules to form Si-O-Si bridges
23- This process proceeds in an inert atmosphere
TEOS can be its own oxygen source, and SiO2 can
be deposited from TEOS in nitrogen - However, addition of oxygen increases the
deposition rate, presumably through providing an
alternative path for removal of the ethyl groups
from the surface - TEOS/O2 is generally performed in tube reactors
at pressures of a few Torr
24- Silicon dioxide
- Silicon dioxide (SiO2) is commonly used in
integrated circuits and nanodevices as an
insulator and as a capacitor dielectric - Silicon dioxide may be deposited by several
different processes - Common source gases include silane and oxygen,
dichlorosilane (SiCl2H2) and nitrous oxide (N2O),
or tetraethylorthosilicate (TEOS Si(OC2H5)4) - The reactions are as follows
- SiH4 O2 ? SiO2 2H2
- SiCl2H2 2N2O ? SiO2 2N2 2HCl
- Si(OC2H5)4 ? SiO2 byproducts
25- The choice of source gas depends on the thermal
stability of the substrate for instance,
aluminum is sensitive to high temperature - Silane deposits at temperatures between 300 and
500 C, dichlorosilane at around 900 C, and TEOS
between 650 and 750 C, resulting in a layer of
Low Temperature Oxide (LTO) - However, silane produces a lower-quality oxide
than the other methods (lower dielectric
strength, for instance), and it deposits
nonconformally - Any of these reactions may be used in LPCVD, but
the silane reaction is also done in APCVD - CVD oxide invariably has lower quality than
thermal oxide, but thermal oxidation can only be
used in the earliest stages of IC manufacturing
26- Silicon dioxide may also be grown with impurities
(alloying or "doping") for one of two purposes - (1) During further process steps that occur at
high temperature, the impurities may diffuse from
the oxide into adjacent layers (most notably
silicon) and dope them - Oxides containing 5 to 15 impurities by mass
are often used for this purpose - (2) silicon dioxide alloyed with phosphorus
pentoxide ("P-glass") can be used to smooth out
uneven surfaces - P-glass softens and reflows at temperatures above
1000 C - This process requires a phosphorus concentration
of at least 6, but concentrations above 8 can
corrode aluminum - Phosphorus is deposited from phosphine gas and
oxygen - 4PH3 5O2 ? 2P2O5 6H2
27- Glasses containing both boron and phosphorus
(borophosphosilicate glass, BPSG) undergo viscous
flow at lower temperatures around 850 C is
achievable with glasses containing around 5
weight of both constituents, but stability in
air can be difficult to achieve - Phosphorus oxide in high concentrations interacts
with ambient moisture to produce phosphoric acid - Crystals of BPO4 can also precipitate from the
flowing glass on cooling - These crystals are not readily etched in the
standard reactive plasmas used to pattern oxides,
and will result in circuit defects in integrated
circuit manufacturing
28- Besides these intentional impurities, CVD oxide
may contain byproducts of the deposition process. - TEOS produces a relatively pure oxide, whereas
silane introduces hydrogen impurities, and
dichlorosilane introduces chlorine - Lower temperature deposition of silicon dioxide
and doped glasses from TEOS using ozone rather
than oxygen has also been explored (350 to 500
C) - Ozone glasses have excellent conformality but
tend to be hygroscopic -- that is, they absorb
water from the air due to the incorporation of
silanol (Si-OH) in the glass - Infrared spectroscopy and mechanical strain as a
function of temperature are valuable diagnostic
tools for diagnosing such problems
29- Silicon Nitride
- Silicon nitride is often used as an insulator and
chemical barrier in manufacturing ICs - Silicon nitride
- The following two reactions deposit nitride from
the gas phase - 3SiH4 4NH3 ? Si3N4 12H2
- 3SiCl2H2 4NH3 ? Si3N4 6HCl 6H2
- Silicon nitride deposited by LPCVD contains up to
8 hydrogen. - It also experiences strong tensile stress , which
may crack films thicker than 200 nm - However, it has higher resistivity and dielectric
strength than most insulators commonly available
in microfabrication (1016 Ocm and 10 MV/cm,
respectively)
30- Another two reactions may be used in plasma to
deposit SiNH - 2SiH4 N2 ? 2SiNH 3H2
- SiH4 NH3 ? SiNH 3H2
- These films have much less tensile stress, but
worse electrical properties (resistivity 106 to
1015 Ocm, and dielectric strength 1 to 5 MV/cm)
31- Vapor-phase Epitaxy (VPE)
- In VPE, one or more materials to be deposited are
transported to the substrate as compounds in
vapor form - In this manner, single materials, doped
materials, or compounds may be deposited in
single crystal form - Once the materials reach the substrate, they are
extracted from the compound and attach themselves
to the surface atoms on the substrate - One of the most common examples of VPE is the
growth of a doped silicon film on a silicon
substrate - This process can be used to fabricate individual
transistors and to fabricate transistors and
isolation regions on integrated circuits
32- There are four major chemical sources of silicon
for commercial epitaxial deposition - 1) silicon tetrachloride (SiCl4)
- 2) trichlorosilane (SiHCl3)
- 3) dichlorosilane (SiH2Cl2)
- 4) silane (SiH4)
- Each of the chemical sources mentioned above may
be described by an over-all reaction equation
that shows how the vapor phase reactants form the
silicon epitaxial film - For example, the over-all reaction for silicon
epitaxy by silane reaction may be written as
follows SiH4 ? Si 2H2
33- Silicon is most commonly deposited from silicon
tetrachloride in hydrogen at approximately 1200
C - SiCl4(g) 2H2(g) ? Si(s) 4HCl(g)
- This reaction is reversible, and the growth rate
depends strongly upon the proportion of the two
source gases - Growth rates above 2 ?m/minute produce
polycrystalline silicon, and negative growth
rates (etching) may occur if too much hydrogen
chloride byproduct is present - An additional etching reaction competes with the
deposition reaction - SiCl4(g) Si(s) ? 2SiCl2(g)
34- The reaction is actually a complex series of
reactions that ultimately result in the
deposition of pure silicon
SiCl4 H2 ? SiHCl3 HCl SiHCl3 H2 ? SiH2Cl2
HCl SiH2Cl2 ? SiCl2 H2 SiHCl3 ? SiCl2
HCl SiCl2 H2 ? Si 2HCl
35- Silicon VPE may also use silane, dichlorosilane,
and trichlorosilane source gases - For instance, the silane reaction occurs at
650 C in this way - SiH4 ? Si 2H2
- This reaction does not inadvertently etch the
wafer, and takes place at lower temperatures than
deposition from silicon tetrachloride - However, it will form a polycrystalline film
unless tightly controlled, and it allows
oxidizing species that leak into the reactor to
contaminate the epitaxial layer with unwanted
compounds such as silicon dioxide
36VPE (vapor phase epitaxy)
- All reactants in vapor phase, deposited on heated
substrate - Halide or hydride process
- I GaAs (s) HCl (g) ? GaCl (g) ¼ As4 (g) ½
H2 (g) - II 3 GaCl (g) ½ As4 (g) ? 2 GaAs (s) GaCl3
(g) - III GaCl (g) ¼ As4 (g) ½ H2 (g) ? GaAs (s)
HCl (g) - Advantage fast rate (.1 - .5 mm.min), easy, safe
(w/o arsine process) - Disadvantage Al compounds difficult, thickness
resolution
halide AsCl3, H2, dopantshydride AsH3, H2,
dopants
Reducing atmosphere
As4
II, III
I
HCl
substrate
halide AsCl3, H2hydride HCl, H2
Ga metal
GaAs
36
37Epitaxial growth
direction of sliding
- LPE (liquid phase epitaxy)
- Thermodynamic equilibrium growth
- saturated melt (As in Ga)
- cool which reduces solubility of As, so GaAs
deposits - can do in bath melt, or slider technique
- advantage inexpensive, easy
- disadvantages
- no in situ diagnostics
- gt binaries hard x x(t)
- surface morphology
- thickness control not very precise
H2 reducing atmosphere
37
38- Metallorganic Chemical Vapor Deposition (MOCVD)
- Metallorganic Chemical Vapor Deposition (MOCVD)
is a method of epitaxial growth of materials,
especially compound semiconductors, from the
surface reaction of organic compounds or
metallorganics and metal hydrides containing the
required chemical elements - For example, indium phosphide could be grown in a
reactor on a substrate by introducing
Trimethylindium ((CH3)3In) and phosphine (PH3)
39- Formation of the epitaxial layer occurs by final
pyrolisis of the constituent chemicals at the
substrate surface. - In contrast to molecular beam epitaxy (MBE) the
growth of crystals is by chemical reaction and
not physical deposition. - This takes place not in a vacuum, but from the
gas phase at moderate pressures (2 to 100 kPa) - As such this technique is preferred for the
formation of devices incorporating
thermodynamically metastable alloys - It has become the dominant process for the
manufacture of laser diodes, solar cells, and LEDs
40Growth Process of MOCVD
41MOCVD Reactor Block Diagram
42- Reactor Components
- A reactor is a chamber made of a high -
temperature material that does not react with the
chemicals being used - The chamber is composed of reactor walls, a
liner, a susceptor, gas injection units, and
temperature control units - The reactor walls are typically made from
stainless steel or quartz - To prevent overheating, cooling water must flow
through the channels within the reactor walls - Special glasses, such as quartz or ceramic, are
often used as the liner in the reactor chamber
between the reactor wall and the susceptor
43- A substrate sits on a susceptor which is held at
a controlled temperature. - The susceptor is made from a material resistant
to the metalorganic compounds used, such as
graphite - For growing nitrides and related materials, a
special coating on the graphite susceptor is
necessary to prevent corrosion by ammonia (NH3)
gas
44- Gas inlet and switching system
- Gas is introduced via devices known as
'bubblers'. - In a bubbler a carrier gas (usually nitrogen or
hydrogen) is bubbled through the metallorganic
liquid, which picks up some metallorganic vapor
and transports it to the reactor - The amount of metallorganic vapor transported
depends on the rate of carrier gas flow and the
bubbler temperature - Allowance must be made for saturated vapors
45- Gas Exhaust and cleaning System
- Toxic waste products must be converted to liquid
or solid wastes for recycling (preferably) or
disposal - Ideally processes will be designed to minimize
the production of waste products
46MOCVD Process
- Basic reaction for GaAs
- Ga(CH3)3AsH3 ? GaAs3CH4
- Al(CH3)3AsH3 ? AlAs3CH4
- For GaN
- Ga(CH3)3NH3 ? GaN3CH4
- Process
- MO sources and hydrides mixed inside reactor and
transferred to the substrate - high temperature of substrate results in the
decomposition of sources, forming the film
precursors. - film precursors transport absorb on the growth
surface - precursors diffuse to the growth site,
incorporate - by-products of the surface reactions absorb from
surface
46
47MOCVD System
47
48- Molecular Beam Epitaxy
- The Molecular Beam Epitaxy System is used to grow
and characterize thin crystalline films of oxides
and ceramics - Molecular beam epitaxy (MBE), is one of several
methods of depositing single crystals - MBE takes place in high vacuum or ultra high
vacuum (10-8 Pa) - The most important aspect of MBE is the slow
deposition rate (typically less than 1000 nm per
minute), which allows the films to grow
epitaxially - However, the slow deposition rates require
proportionally better vacuum in order to achieve
the same impurity levels as other deposition
techniques
49- In solid - source MBE, ultra - pure elements such
as gallium and arsenic are heated in separate
quasi-Knudsen effusion cells until they begin to
slowly sublimate - The gaseous elements then condense on the wafer,
where they may react with each other - In the example of gallium and arsenic,
single-crystal gallium arsenide is formed. - The term "beam" simply means that evaporated
atoms do not interact with each other or any
other vacuum chamber gases until they reach the
wafer, due to the long mean free paths of the
atoms
50- During operation, RHEED (Reflection High Energy
Electron Diffraction) is often used for
monitoring the growth of the crystal layers - A computer controls shutters in front of each
furnace, allowing precise control of the
thickness of each layer, down to a single layer
of atoms. - Intricate structures of layers of different
materials may be fabricated in this manner - Such control has allowed the development of
structures where the electrons can be confined in
space, giving quantum wells or even quantum dots - Such layers are now a critical part of many
modern semiconductor devices, including
semiconductor lasers and light-emitting diodes
51- In systems where the substrate needs to be
cooled, the ultra-high vacuum environment within
the growth chamber is maintained by a system of
cryopumps and cryopanels, chilled using liquid
nitrogen or cold nitrogen gas to a temperature
close to 77 oK (-196 oC) - However, cryogenic temperatures act as a sink for
impurities in the vacuum, and so vacuum levels
need to be several orders of magnitude better to
deposit films under these conditions - In other systems, the wafers on which the
crystals are grown may be mounted on a rotating
platter which can be heated to several hundred oC
during operation
52- Molecular beam epitaxy is also used for the
deposition of some types of organic
semiconductors - In this case, molecules, rather than atoms, are
evaporated and deposited onto the wafer - Other variations include gas-source MBE, which
resembles chemical vapor deposition
53MBE
53
5454
55Growth process
- UHV (lt 10-8)
- Knudsen sources
- As flux, sticking coeff. lt 0.5
- growth JIII excess JV
- high As/Ga flux, low T - As stabilized
- low As/Gas flux, high T - Ga stabilized
Congruent sublimation Tcs (C)GaAs 650AlAs 850A
lP gt700GaP 670InP 363InAs 380 if T lt Tcs,
group V stable if T gt Tcs, group III stable
55
56Comparison of Epitaxial Methods
limit
features
time
Growth method
Limited substrate areas and poor control over the
growth of very thin layers
Growth form supersaturated solution onto
substrate
1963
LPE (Liquid phase epitaxy)
No Al contained compound, thick layer
Use metal halide as transport agents to grow
1958
VPE (Vapor phase epitaxy
Hard to grow materials with high vapor pressure
Deposit epilayer at ultrahigh vacuum
1958 1967
MBE (Molecular Beam Epitaxy)
Some of the sources like AsH3 are very toxic.
Use metallorganic compounds as the sources
1968
MOCVD (Metal-Organic Chemical Vapor Deposition)
56
57Atomic Layer Epitaxy (ALE)
- Atomic layer epitaxy (ALE), or Atomic Layer
Deposition (ALD), is a specialized form of
epitaxy that typically deposit alternating
monolayers of two elements onto a substrate,
making it ideal to generate nanostructures - The crystal lattice structure achieved is thin,
uniform, and aligned with the structure of the
substrate - The reactants are brought to the substrate as
alternating pulses with "dead" times in between.
ALE makes use of the fact that the incoming
material is bound strongly until all sites
available for chemisorption are occupied - The dead times are used to flush the excess
material
58- Atomic layer epitaxy (ALE) or atomic layer
deposition (ALD) is a technique mostly used in
semiconductor fabrication to grow thin films of
thickness of the atomic order - The main approach used for this technique is the
use of a self limiting chemical reaction to
control in a very accurate way the thickness of
the film deposited - Compared to basic CVD for example, chemical
reactants are pulsed alternatively in a reacting
chamber and then chemisorb on to the surface of
the substrate in order to form the monolayer - The reaction is very easy to set up and doesnt
require that many restrictions over the
reactants, allowing the use of a wide range of
materials
59- ALE introduces two complementary precursors (e.g.
Al(CH3)3 and H2O) alternatively into the reaction
chamber. - Typically, one of the precursors will adsorb onto
the substrate surface, but cannot completely
decompose without the second precursor. - The precursor adsorbs until it saturates the
surface and further growth cannot occur until the
second precursor is introduced - Thus the film thickness is controlled by the
number of precursor cycles rather than the
deposition time as is the case for conventional
CVD processes - In theory ALCVD allows for extremely precise
control of film thickness and uniformity