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In this work we report the adhesion of a thin Tantalum (Ta) barrier films deposited on nanoporous dielectric substrates (Xerogel and Methyl Silesquioxanes (MSQ)). The high compressive stresses in the Ta barrier layer lead to spontaneous delamination from the underlying substrate resulting in a telephone cord like morphology, which allows the measurement of critical interfacial adhesion (fracture) energy. The fracture energy of Ta barrier films on different porous substrates is evaluated using the above two methods and the resulting differences are explained. Fracture energy varies inversely as a power law with the dielectric pore size indicating pores are essential to delamination in the barrier-dielectric interface. The observed trend of fracture energy is related to other mechanical properties of the porous substrate offering insights into the underlying mechanisms governing fracture of films deposited on porous substrates.

Glow discharge amorphous hydrogenated silicon (a-Si:H) prepared at near room temperature typically results in an inhomogeneous morphology that is undesirable for a number of thin film applications. The most commonly observed features of this include columnar morphology and surface roughness. This usually results from anodic deposition, where substrates are placed on the grounded electrode. We have discovered that placing substrates on the RF-powered electrode (referred to as cathodic deposition) offers a much wider processing range for homogenous growth than anodic growth. We have also found that the magnitude of the surface roughness and the bulk void fraction of both anodic and cathodic a-Si:H thin films processed at low-temperatures is proportional to ∼D/F, where D is the surface diffusivity and F, the adatom flux, though anodic and cathodic deposition affect these global parameters differently. Surface processes unique to cathodic deposition can enhance adatom surface diffusion, while diffusion during anodic deposition is fixed and cannot attain homogeneous growth at high adatom fluxes. Processing a-Si:H on the cathode, associated with enhanced adatom surface diffusion, allows for homogeneous growth even at high deposition rates that has benefits for a number of applications.

Surface topography of a-Si:H thin films, deposited at 75°C by Plasma-enhanced Chemical Vapor Deposition (PECVD) has been examined using helium/silane feedstock mixtures under different substrate bias conditions. Notable differences in the surface roughness evolution are shown for films deposited in “cathodic” versus “anodic” mode – where the substrate is placed on the powered and grounded electrode respectively. Smooth and apparently featureless surfaces result from deposition on RF powered surfaces, upon which a self-bias induces high-energy ion bombardment. Rougher surfaces result from films deposited on electrically grounded surfaces. These anodic films show that after a transition period, surface roughness grows linearly with processing time, exhibiting mounded type growth as evidenced by 2-D power spectral density functions of surface height measurements. Linear growth in roughness has been predicted for shadow growth models assuming film precursor sticking coefficients of one and random angle approach of film precursor species. Growth of this nature has not been reported before in a-Si:H studies, which usually assume directional deposition conditions and sticking coefficients less than unity – occurring even at low processing temperatures.

Surface or interface roughness can impact optical, electronic, and MEMS applications of thin a-Si:H films. Deposition at lower temperatures can be advantageous for some applications of a-Si:H, but lower temperature deposition generally leads to rougher films. We have found that the evolution of surface roughness growth can be modified substantially by ion bombardment due to the self-bias of the plasma during Plasma-Enhanced Chemical Vapor Deposition (PECVD). Notable differences in the surface roughness evolution and deposition rate are shown for films deposited in “cathodic” versus “anodic” mode – where the substrate is placed on the powered and grounded electrode respectively. Suppression of surface roughness growth of a-Si:H can be achieved under conditions of relatively high ion bombardment even at deposition temperatures as low as 75 C. Atomic force microscopy (AFM) was used to measure the relative surface roughness profile as a function of deposition time. Analysis of the power spectral density of the roughness yielded important statistical surface parameter information. Based on these observations, insight is given into growth mechanisms under the two deposition conditions.

Optical waveguides are being explored for on-chip purposes to overcome the speed limitations of electrical interconnects. Passive optical components like waveguides and vertical outcouplers are important components in such schemes. In this study we fabricate planar waveguides with integrated vertical micro-mirrors using standard Back End of the Line silicon (BEOL) CMOS based processes. Around 1.6 μm of a hybrid alkoxy siloxane polymer with a refractive index of ∼ 1.50 at the intended wavelength of 830 nm is used as the core and plasma deposited silicon oxide with a refractive index of ∼ 1.46 is used as the cladding. The angular face in the polymer waveguide that would function as the mirror surface was fabricated by a pattern transfer method which involves transferring the angle in a template to the waveguide using anisotropic reactive ion etching. The sidewall angle realized in a positive resist on patterning was used as the angle template. Exposure and development conditions were adjusted for Shipley® S1813 photoresist to generate a sidewall angle of ∼ 65°. The anisotropic Reactive Ion Etching (RIE) was done using a CF4/O2 plasma chemistry. A gas composition of 50/50 CF4/O2 was chosen in order to minimize the etch related roughness of the polymer and the photoresist. The metallization of the mirror faces was done using a self-aligned maskless technique which ensures metal deposition only on the angular face and also eliminates a lithography step.

Surface modified silica xerogel films of high porosity (25-90 %) and uniform thickness (0.4-2 µm) were fabricated at ambient pressure on silicon and other substrates. Mechanical reliability of the films was determined by measuring fracture toughness (adhesive) as a function of aging time and temperature using the modified edge-lift-off technique. There is an optimum aging time at 60 °C aging to obtain maximum fracture toughness for the procedure used here.Cu/xerogel/Si and Ta/xerogel/Si structures were annealed at different temperatures and in different ambient environments were analyzed using RBS and optical microscopy to assess the extent of interaction with the xerogel film. When annealed in N2 with trace amounts of O2 (equivalent to 10-7-10-6 Torr vacuum), RBS analysis does not show diffusion of Cu or Ta through the xerogel up to 450 °C. At higher temperatures, or in the presence of larger concentrations of O2, Cu and Ta oxidize. Cu oxidation leads to significant diffusion through the xerogel. Ta oxidation also results in diffusion-like RBS spectra. Using the micron-size ion beam to probe the Ta surface, this was found to be solely due to buckling of Ta films on xerogel. A thin SiNx layer on top of Cu and Ta prevents metal oxidation up to 640 °C, Cu diffusion, and Ta buckling.

Surface modified silica xerogel films of high porosity (60 - 90 %) and uniform thickness (0.4–2 μm) were fabricated at ambient pressure on silicon and silicon dioxide. The rheological properties that govern film uniformity were determined. A relation between the final dried film thickness and spin speed was developed. The porosity and thickness of the films could be controlled independently. The same porosity could be obtained over a wide range of aging time and temperature combinations. Fracture toughness was measured using the edge-lift-off technique. The best values were comparable to concrete. Surface modification was affected by treating the film with trimethylcholorosilane (TMCS) and other modifiers. Moisture adsorption was studied at 100% RH using a quartz crystal microbalance technique. Depending upon the degree and kind of surface treatment, films absorbed as much as 32% or as little as 2% of their weight in water. Dielectric constants (K), losses and breakdown strengths were comparable to values for calcined, bulk aerogels. Thin (≤ 500 Å) films of Copper (Cu) and Tantalum (Ta) were deposited on xerogel films and subjected to thermal annealing. No diffusion was observed within the limits of RBS. High-density plasma etching showed that the films etch an order of magnitude faster than conventional SiO2 films.

Optical communications are becoming technologically important on progressively shorter length scales. As computer chip speeds increase longer metal wire interconnects become problematic and may limit device performance. Wide bandwidth optical interconnects may be used to address this problem. Silicon oxide and silicon nitride were explored as prospective optical and processing materials in the making of optical interconnects. Etching of slopes, which would be an important process for making optical interconnects, was studied. Slopes with angles ranging from 5 to 50 degrees were fabricated using a silicon oxide / silicon nitride stack.

In this work. we report on characterization methods and the optical properties of a polyimide (Ultradel 9020D). The prism coupling technique was used to couple light into polyimide thin films. The scattered light from the surface was imaged to determine the optical loss at different wavelengths. The coupling angle was used to find the refractive index of the films. The stability of the polymer in terms of refractive index and absorption losses was studied by heat treatment under nitrogen at elevated temperatures. No significant change was observed in the properties of the film at annealing temperatures below 200°C. The bulk and surface losses were separated and it was found that the waveguide losses were dominated by bulk losses. Temperature stability of the polymer was evaluated by annealing the polymer at 125°C for up to 30 hours. No significant changes were seen in the optical losses for these times.

A quantitative characterization of the thermal properties is required to assess the thermal performance of low dielectric constant materials. Recently we have developed a technique based on the 3-omega method for measuring the thermal conductivity of porous dielectric thin films. In this paper we present the results on the measurements of thermal conductivity of thin porous films using this method. A finite element method analysis is used to evaluate the approximations used in the measurement. Two porosity-weighted thermal resistor models are proposed to interpret the results. By studying the dependence of the thermal conductivity on porosity, we are able to discuss the scaling rule of thermal conductivity. Additionally, a steady state layered heater model is used for evaluating the significance of introducing porous ILDs into an interconnect structure.

Ion beam analysis techniques have become very useful for characterization of low k materials. Studies on several ion beam analysis techniques will be discussed. Rutherford Backscattering Spectrometry (RBS) provides a very powerful analytical technique for the thickness and porosity measurements on porous Si0 2 films. Nuclear Reaction Analysis (NRA) techniques for hydrogen and fluorine profiling are very useful to characterize fluorinated polymer and fluorinated oxide films. Examples of low k materials including Si02:F, Parylene-AF and Teflon-AF will be discussed. Fluorine diffusion in to metals and various interface effects between metal and low k materials will be presented.

Xerogel films of high porosity were fabricated using an ambient pressure technique. The same porosity can be obtained with different microstructures by varying the aging time of the films. The dielectric constant of these films as a function of porosity at 1 MHz follows correlations originally developed for bulk aerogels. Diffusion of copper is orders of magnitude faster in these xerogels than in the corresponding thermal oxide. An activation energy of 0.9 eV was estimated based on a convective diffusion model.

Nonlinear optical materials which are highly transparent and show large second harmonic generation coefficients were fabricated via the sol-gel process. Nonlinear chromophores were directly incorporated into the silica network by polymerizing chromophore containing organo silanes such as N-[3-(Triethoxysilyl)propyl]-2, 4-dinitrophenylamine (TDP) and 3-(4-Formyl phenoxy)propyl trimethoxy silane (FPT).