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The ultra-low k dielectrics have been widely used as semiconductor technology steps into 45 nm, 28 nm, and more advanced nodes. Combined with the rapid shrinks of critical dimensions, the ultra-low k dielectrics face challenges to retain the benefits of interconnect scaling both on their manufacturability and reliability performances. In this paper, abnormal failure phenomena were investigated on 28 nm ILD (Intra Level Dielectric) and IMD (Inter Metal Dielectric) qualifications and 40 nm mass production. A new failure mechanism of metal 1 to poly (M1-to-poly) leaky path was proposed based on theoretical investigations and experiments. Based on our newly proposed dielectric breakdown mechanism, a series of innovative test structures were designed for early detections and evaluations of reliability performances. These newly designed test structures have been proven to be useful due to better representing actual using profiles, more precise reliability evaluations, and more effective monitors on process variations at mass production. [ABSTRACT FROM AUTHOR]

The effects of baking temperature on back-end-of-line (BEOL) reliability were explored on 28 nm technology node. We found that stress migration (SM) worse temperature showed up around 200 °C and apparent negative resistance (R) shifts appeared after baking at high temperatures. The Electromigration (EM) performance behaved the temperature dependence and the high baking temperature improved the main time-to-failure (TTF) distribution. Interlayer dielectric (ILD) time dependence dielectric breakdown (TDDB) performance was enhanced at low baking temperatures. [ABSTRACT FROM AUTHOR]

With technologies scaling down to 28 nm and below, and HKMG (High-κ Metal Gate) process being introduced, the NMOS PBTI (Positive Bias Temperature Instability) becomes a reliability concern due to the higher pre-existing trap density in the HfO 2 film. These traps can lead to electron trapping and device parameters shifts. Degradation of Vccmin read is a dominant factor in SRAM Vccmin degradations, and PD (Pull Down) NMOS PBTI degradation dominates the Vccmin read degradation, especially at HKMG development phase because of the un-optimized HK dielectric process. This paper provides a feasible methodology to evaluate chip level HTOL (High Temperature Operation Life) performance based on device level PBTI test by studying a correlation relationship between device Vt degradation in WLR (Wafer-Level Reliability) NMOS PBTI stressed tests and SRAM Vccmin degradation in HTOL tests. The proven correlation model allows characterization of Vccmin shifts in SRAM HTOL through WLR PBTI tests at HKMG development, and therefore has significant impacts in promoting reliability test efficiency and reduces development times. [ABSTRACT FROM AUTHOR]

The NBTI (negative bias temperature instability) performance of 28 nm HfO 2 -based HKMG (high-κ metal gate) I/O thick oxide p-MOSFETs with different I/O oxide processes is reported. The results show that the NBTI performance from ISSG (in-situ steam generation) process is better than that from the furnace Gox1 process. The NBTI dependence on the PDA (post deposition anneal) process is studied and we show that PDA can significantly improve NBTI. We investigate the influence of DPN (decoupled plasma nitridation) on NBTI; the NBTI performance from the DPN process is much better than that from non-DPN processes for the devices with the same EOT (electrical oxide thickness). Based on the experiments, we propose an extended NBTI model, which incorporates nitrogen concentration in the formula for the process with DPN. This extension provides much clearer direction on process tuning to better control the DPN dosage and the EOT to meet both process electric and reliability requirements. [ABSTRACT FROM AUTHOR]

In this paper, some practical considerations for effective and efficient wafer-level reliability control (WLRC) are presented. We propose a better solution to replace the previous method by adding a protection diode to avoid process induced charging damage on test structure devices. This work also provides in-depth discussions on WLR Via electromigration (EM), which correlated well with traditional time-consuming package-level tests. In addition, due to the time constraint at WLRC, some real cases are discussed regarding the suitable sampling plan and test structures. These studies are to improve WLRC effectiveness and efficiency, to diagnose reliability concerns, to expedite WLRC failure analyses when out-of-control, and, thus, to facilitate WLRC lot dispositions. [Copyright &y& Elsevier]

This paper depicts the improvement of poly-silicon (poly-Si) holes induced failures during gate oxide integrity (GOI) voltage-ramp (V-Ramp) tests by replacing plasma enhanced oxidation with silicon rich oxidation (SRO), which is cap oxide on transfer gate serving as a hard mask to selectively form salicide. The SRO was found to be capable of completely removing salicide block etching induced poly-Si holes. With this SRO film deposited on poly-gate, the higher density silicon in cap oxide fills the interface of poly-Si grains and repairs the poly-Si film damaged by source–drain (S/D) implantation. The plasma-induced damage (PID) effect is observed and SRO can also suppress this PID effect and, thus, enhance GOI process margin. This is because PID may be enhanced during plasma poly-Si etching and S/D implantation, which induces the under-layer latent defects and deteriorates the adhesion between poly-grains and oxide. The SRO refraction index, which is 1.56 in this study with maximum silane (SiH4) in cap oxide furnace, was found to play an important role on eliminating poly-holes. In-line SEM inspections show that poly-Si holes happen at open area such as the GOI test patterns of large bulk area and of poly-Si edge. Therefore, in-line defect inspections, which usually check only cell area, fail to find poly-Si holes. Hence, the in-line GOI monitor is proposed to detect such “hidden” defects. In this paper, we found SRO can successfully eliminate poly-Si holes, which lead to GOI failures, with minimum productivity loss and negligible process costs. Since GOI monitor by V-Ramp test is implemented to detect such reliability failure, wafer-level reliability control is recommended to proactively monitor and improve GOI performance. In order to achieve more stringent reliability targets as technology marches to the 0.10 μm era, we introduce the concepts of build-in reliability to facilitate qualifications and to incorporate related/prior reliability concerns for developing advanced processes. [Copyright &y& Elsevier]