Abstract:
A multi-stage silicidation process is described wherein a dielectric etch to expose contact regions is timed to be optimal for a highest of the contact regions. After exposing the highest of the contact regions, a silicide is formed on the exposed contact region and the dielectric is re-etched, selective to the formed silicide, to expose another contact region, lower than the highest of the contact regions, without recessing the highest of the contact regions. The process then forms a silicide on the lower contact region. The process may continue to varying depths. Each subsequent etch is performed without the use of additional masking steps. By manipulating diffusive properties of existing silicides and deposited metals, the silicides formed on contact regions with differing depths/height may comprise different compositions and be optimized for different polarity devices such as nFET and pFET devices.

Description:
FIELD OF THE INVENTION 
     This disclosure relates generally to semiconductor devices and more specifically to the formation of silicides on conductive features of semiconductor devices. 
     BACKGROUND OF THE INVENTION 
     The fabrication of semiconductor devices involves forming electronic components in and on semiconductor substrates, such as silicon wafers. These electronic components may include one or more conductive layers, one or more insulation layers, and doped regions formed by implanting various dopants into portions of a semiconductor substrate to achieve specific electrical properties. Semiconductor devices include transistors, resistors, capacitors, and the like, with intermediate and overlying metallization patterns at varying levels, separated by dielectric materials, which interconnect the semiconductor devices to form integrated circuits. 
     Silicides (metal-semiconductor alloys) are used in the semiconductor industry to enhance signal propagation through transistors and other conductive features of semiconductor devices. A silicide has a lower resistance than the underlying doped silicon or poly. As a result, contact resistance is reduced and signal propagation through the semiconductor device is enhanced. 
     Current nanoscale semiconductor devices employ embedded conductive regions, such as source/drain (S/D) regions for a field effect transistor (FET). For different device regions and various devices (e.g., nFET, pFET), these embedded conductive regions may be grown with different overfills. For example, S/D regions in one device region may be raised above a semiconductor substrate farther than S/D regions in a second device region. In another example, S/D regions in the second device region may not be raised above the substrate at all. 
     Since known etching methods have poor selectivity to typical semiconductor substrates (e.g., Si, SiGe, SiC), to expose conductive regions of a plurality of semiconductor devices in a substrate, a timed etch, such as a reactive-ion etch (RIE), is used, with the time determined by the lowest of the conductive regions to ensure that good contact is made to all conductive regions. A consequence of this is that the conductive regions with a higher overfill end up with significant recessing that can cause device performance degradation and/or high junction leakage. 
     The characteristics of the silicide, e.g., thickness, resistance, and the like, may be controlled through various parameters such as the type of metal, annealing time and temperature, etc. 
     SUMMARY 
     One aspect of an embodiment of the present invention discloses a method for forming silicides on a plurality of device contact regions with different overfill heights. The method comprises forming a dielectric layer over the plurality of device contact regions on a semiconductor substrate. The method further comprises etching contact openings into the dielectric layer over each of the plurality of device contact regions to a depth sufficient to expose at least one of the plurality of device contact regions, but insufficient to expose at least one other of the plurality of device contact regions. The method further comprises forming a first silicide on the at least one of the plurality of device contact regions. The method further comprises extending the contact openings in the dielectric layer, via an etch selective to the first silicide on the at least one of the plurality of device contact regions, to expose the at least one other of the plurality of device contact regions, and forming a second silicide on the at least one other of the plurality of device contact regions. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       The following detailed description, given by way of example and not intended to limit the disclosure solely thereto, will best be appreciated in conjunction with the accompanying drawings, in which: 
         FIG. 1  depicts two conventional transistor structures comprising respective source/drain regions on opposite sides of respective gate stacks, separated by an isolation region and covered by a dielectric layer. 
         FIG. 2  depicts the deposition of an etch mask over the dielectric layer of  FIG. 1  exposing areas of the dielectric layer over the respective source/drain regions of  FIG. 1 . 
         FIG. 3  depicts the dielectric layer of  FIG. 1  etched to form contact openings through the dielectric layer and expose the higher of the source/drain regions from  FIG. 1 . 
         FIG. 4  depicts the formation of a silicide on the exposed source/drain regions from  FIG. 3 , in accordance with an embodiment of the present invention. 
         FIG. 5  depicts the exposure of the lower of the source/drain regions from  FIG. 1 . 
         FIG. 6  depicts the formation of a silicide on the exposed source/drain regions of  FIG. 5 , in accordance with an embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     Detailed embodiments of the claimed structures and methods are disclosed herein. The method steps described below do not form a complete process flow for manufacturing integrated circuits. The present embodiments can be practiced in conjunction with the integrated circuit fabrication techniques currently used in the art, and only so much of the commonly practiced process steps are included as are necessary for an understanding of the described embodiments. The figures represent cross-section portions of a semiconductor chip or a substrate during fabrication and are not drawn to scale, but instead are drawn to illustrate the features of the described embodiments. Specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the methods and structures of the present disclosure. 
     For purposes of the description hereinafter, the terms “upper”, “lower”, “right”, “left”, “vertical”, “horizontal”, “top”, “bottom”, and derivatives thereof shall relate to the disclosed structures and methods, as oriented in the drawing figures. The terms “overlying”, “atop”, “over”, “on”, “positioned on” or “positioned atop” mean that a first element is present on a second element wherein intervening elements, such as an interface structure, may be present between the first element and the second element. The term “direct contact” means that a first element and a second element are connected without any intermediary conducting, insulating or semiconductor layers at the interface of the two elements. 
     Sequential steps of an exemplary embodiment of the method of performing a multi-stage silicidation process on semiconductor devices is described below with respect to the schematic illustrations of  FIGS. 1-6 . Similar reference numerals denote similar features. 
     Referring first to  FIG. 1 , two conventional transistor structures are shown comprising a substrate  100  doped with either an N-type impurity or P-type impurity, raised source/drain regions  102  on opposite sides of gate stack  104  to form field effect transistor (FET)  106 , and source/drain regions  108  on opposite sides of gate stack  110  to form FET  112 . FET  106  and FET  112  are separated by isolation region  114 . Although the present disclosure provides details concerning forming silicides on contact regions (such as source/drain regions  102  and  108 ) of FETs  106  and  112 , the process disclosed herein may form silicides on contact regions of any number of semiconductor devices including, but not limited to, memory devices, resistors, diodes, capacitors, complementary metal oxide semiconductor (CMOS) devices, bipolar junction transistor (BJT) semiconductor devices, schottky barrier semiconductor devices, and finFET semiconductor devices. 
     Substrate  100  may be composed of a silicon containing material. Silicon containing materials include, but are not limited to, Si, single crystal Si, polycrystalline Si, SiGe, single crystal silicon germanium, polycrystalline silicon germanium, or silicon doped with carbon, amorphous Si and combinations and multi-layers thereof. Semiconductor substrate  100  may also be composed of other semiconductor materials, such as germanium, and compound semiconductor substrates, such as type III/V semiconductor substrates, e.g., GaAs. Although semiconductor substrate  100  is depicted as a bulk semiconductor substrate, semiconductor on insulator (SOI) substrate arrangements, such as silicon on insulator substrates, are also suitable for semiconductor substrate  100 . 
     As is common, source/drain regions  102  and  108  have a conductivity opposite to that of substrate  100 . Doped P-wells or N-wells (not shown) may be used to adjust the conductivity of substrate  100  in various device regions. Source/drain regions  102  are “raised” source/drain regions wherein a portion of the respective source/drain region rises out of semiconductor substrate  100  and another portion of the respective source/drain region resides within semiconductor substrate  100 . Source/drain regions  108  do not rise above the surface of substrate  100 . In another embodiment, source/drain regions  108  may be raised source/drain regions, but raised to a different height than source/drain regions  102 . A portion of a source/drain region raised above the substrate may be referred to as an “overfill”. Each of source/drain regions  102  and source/drain regions  108  may include extension dopant regions  116 , decreasing channel length for FETs  106  and  112 , respectively. 
     Gate stacks  104  and  110  include respective gate conductors  118  and  120  atop respective gate dielectrics  122  and  124 . Gate conductors  118  and  120  may be metal gate electrodes. Gate conductors  118  and  120  may be composed of any conductive metal including, but not limited to, W, Ni, Ti, Mo, Ta, Cu, Pt, Ag, Au, Ru, Ir, Rh, and Re, and alloys that include at least one of the aforementioned conductive elemental metals. In another embodiment, gate conductors  118  and  120  may also be composed of a doped semiconductor material, such as n-type doped polysilicon. Gate dielectrics  122  and  124  may be a dielectric material, such as SiO 2 , or alternatively a high-k dielectric, such as oxides of Hf, Ta, Zr, Al or combinations thereof. In another embodiment, gate dielectrics  122  and  124  are comprised of an oxide, such as ZrO 2 , Ta 2 O 5  or Al 2 O 3 . In one embodiment, gate dielectrics  122  and  124  have a thickness ranging from 1 nm to 10 nm. In another embodiment, the gate dielectrics  122  and  124  have a thickness ranging from 1.0 nm to 2.0 nm. 
     In an alternative embodiment, gate stacks  104  and  110  may be sacrificial gate stacks to be subsequently removed in a replacement gate process. Sacrificial gate material may be any material, such as polysilicon, that may be etched selectively to a surface of substrate  100 . 
     Spacers  126  and  128  may be in direct contact with the sidewalls of respective gate stacks  104  and  110 . Spacers  126  and  128  typically have a width ranging from 2.0 nm to 15.0 nm, as measured from the sidewall of respective gate stack  104  and  110 . Spacers  126  and  128  may be composed of a dielectric, such as a nitride, oxide, oxynitride, or a combination thereof. 
     Dielectric layer  130  is formed over FETs  106  and  112 . Dielectric layer  130  may be composed of any dielectric material including, but not limited to, oxides, nitrides, oxynitrides, silicate glass and combinations thereof. In one example, dielectric layer  130  may be composed of a silicon nitride film. In another example, dielectric layer  130  is composed of a silicon oxide film. In yet another example, dielectric layer  130  comprises a film stack consisting of a silicon nitride film and a silicon oxide film. The upper surface of dielectric layer  130  may be coplanar with an upper surface of gate stacks  104  and  110 . In another embodiment, dielectric layer  130  is present on the upper surfaces of gate stacks  104  and  110 . 
     Although only two semiconductor devices (FET  106  and FET  112 ) are shown on substrate  100 , any number of semiconductor devices may be formed on substrate  100  with any number of varied contact region overfills in various embodiments. 
       FIG. 2  depicts the deposition of etch mask  132  over dielectric layer  130  to expose areas of dielectric layer  130  over source/drain regions  102  and  108 . Etch mask  132  may comprise any etch resistant material. For example, a photoresist etch mask can be produced by applying a photoresist layer to the upper surface of dielectric layer  130 , exposing the photoresist layer to a pattern of radiation, and then developing the pattern into the photoresist layer utilizing a resist developer. The photoresist etch mask may be positioned so that portions of dielectric layer  130  are not protected by the photoresist etch mask. Alternatively, a photoresist etch mask may be deposited over a hardmask and used to etch openings into the hardmask. The hardmask would serve as etch mask  132  for subsequent etch processes. A hardmask may be preferable as it is not as easily degraded during etch processes such as plasma etching. A hardmask may be made up of, by way of example, titanium nitride, silicon nitride, silicon dioxide, silicon carbide, silicon carbide nitride and/or combinations of the preceding. 
     As depicted in  FIG. 3 , dielectric layer  130  is etched to form contact openings (e.g., contact openings  134  and  136 ) through dielectric layer  130  and expose source/drain regions  102 . Contact openings  134  and  136  may be formed using photolithography and etch processes. 
     The exposed portions of dielectric layer  130  are removed by a selective etch. However, known etch processes have poor selectivity to substrate materials, such as Si, SiGe, and SiC, and the depth of the etch is largely determined by a time of exposure to the etch process. The etch process may be an anisotropic etch or an isotropic etch. The anisotropic etch may include reactive-ion etching (RIE). Other examples of anisotropic etching that can be used at this point of the present disclosure include ion beam etching, plasma etching or laser ablation. An isotropic etch, such as a wet chemical etch, removes the material being etched at the same rate in each direction. Isotropic etch processes are contrary to anisotropic etch processes, which preferentially etch in one direction, such as with a reactive ion etch (RIE). 
     Traditionally, the etch process was set to a time optimized for the lowest contact region, in the depicted example, source/drain regions  108 . At the point that the lowest contact region would be exposed, higher contact regions (regions with greater overfill) such as source/drain regions  102  would be significantly recessed. Contrary to the traditional approach, the depicted etch process is set to a time optimized for the higher of the contact regions, source/drain regions  102 , leaving source/drain regions  108  at least partially covered by dielectric layer  130 . 
       FIG. 4  depicts the formation of silicide  138  within contact openings  134 , in accordance with an embodiment of the present invention. 
     A silicide structure is created through thermal diffusion that is induced by annealing metal and semiconductor containing materials that are in contact to produce a homogenous mixture or solid solution. In one embodiment of the present disclosure, a metal containing layer is deposited over FETs  106  and  112  including over source/drain regions  102  exposed through contact openings  134 . During the annealing process metal elements from the metal containing layer are diffused into a portion of source/drain regions  102  to form silicide  138 . 
     The metal containing layer may be deposited using physical vapor deposition (PVD) methods or chemical vapor deposition (CVD) methods. Examples of physical vapor deposition (PVD) techniques that are suitable for forming the metal containing layer include sputtering and plating. As used herein, “sputtering” means a method of depositing a film of material on a semiconductor surface. A target of the desired material, i.e., source/drain regions  102 , is bombarded with particles, e.g., ions, which knock atoms from the target, and the dislodged target material deposits on the semiconductor surface. Examples of sputtering apparatuses include DC diode type systems, radio frequency (RF) sputtering, magnetron sputtering, and ionized metal plasma (IMP) sputtering. In different embodiments, the metal containing layer may be conformal or non-conformal. The term “conformal” denotes a layer having a thickness that does not deviate by more than 20% of an average value for the thickness of the layer. 
     In one example, the metal containing layer may be composed of nickel or nickel platinum alloy. The metal containing layer may also include at least one of nickel (Ni), cobalt, (Co), tungsten (W), titanium (Ti), tantalum (Ta), aluminum (Al), platinum (Pt) and combinations thereof. The metal containing layer may have a thickness ranging from 5 nm to 20 nm. In another embodiment, the metal containing layer may have a thickness ranging from 6 nm to 15 nm. 
     Following deposition of the metal containing layer, the entire structure is subjected to an annealing step including, but not limited to, rapid thermal annealing. During annealing, the deposited metal containing layer reacts with the semiconductor material of source/drain regions  102  forming a silicide  138 . A typical thermal anneal is completed at a temperature ranging from 350° C. to 600° C. for a time period ranging from 1 second to 90 seconds. Following thermal anneal, the non-reacted portion of the metal containing layer is removed. The non-reacted portion of the metal containing layer may be removed by an etch process that is selective to silicide  138 . The etch process may optionally remove etch mask  132 . 
     In an alternate embodiment, a semiconductor containing material may be deposited on source/drain regions  102  prior to the metal containing layer. 
       FIG. 5  depicts the exposure of source/drain regions  108 . Dielectric layer  130  is exposed to a subsequent etch process, such as a RIE, for a time optimized to extend contact opening  136  to expose source/drain regions  108  and selective to silicide  138 . No intermediate masking steps are performed. Because silicides have a higher selectivity than typical substrates, the recessing into source/drain regions  102  is reduced or eliminated. 
       FIG. 6  depicts the formation of silicide  140  over source/drain regions  108 , in accordance with an embodiment of the present invention. 
     Similar to the process of forming silicide  138 , a metal containing layer is deposited over FETs  106  and  112  and over source/drain regions  108 . A thermal anneal allows the metal to diffuse into the semiconductor containing material of source/drain regions  108 , to create silicide  140 . The non-reacted portion of the metal containing layer is removed. 
     In one embodiment a similar metal containing layer may be used for both of silicides  138  and  140 . In such an embodiment, silicide  138  may receive more metal atoms from the metal containing layer used to create silicide  140 . 
     In an alternate embodiment, it may be desirable to have silicides  138  and  140  composed of different metals. For example, a valence band edge silicide such as platinum silicide (PtSi), iridium silicide (IrSi), or nickel platinum silicide (NiPtSi) is desirable for pFET devices. A conduction band edge silicide such as erbium silicide (ErSi) or ytterbium silicide (YbSi) is desirable for nFET devices. For discussion purposes, FET  106  represents an nFET device and FET  112  represents a pFET device. When forming silicide  138 , the metal containing layer may contain Er, which is annealed to form silicide  138  as ErSi on source/drain regions  102 . Source/drain regions  108  are protected by dielectric layer  130  and the remainder of the Er containing layer is removed. Subsequent to the etch exposing source/drain regions  108 , a metal containing layer is deposited that may contain Ni and Pt. The Ni and Pt containing layer is over source/drain regions  108  and silicide  138  on source/drain regions  102 . It would be undesirable to diffuse Ni and Pt into silicide  138  in this example. However, because silicide  138  is less diffusive than the semiconductor containing material of source/drain regions  108 , a two-step silicidation process may be used where a low-temperature anneal diffuses Ni and Pt atoms into source/drain regions  108 , but is not hot enough to diffuse Ni and Pt atoms into silicide  138 . Excess metal is stripped and after silicide  138  is cleared of the metal containing layer, a high temperature anneal is used to complete silicide  140  as NiPtSi on source/drain regions  108  without affecting silicide  138 . 
     As an alternative, or in addition to, a two-step silicidation process on silicide  140 , metal elements with different diffusive properties may be used in the respective metal containing layers used to create silicide  138  and  140 . For example, tungsten diffuses into a semiconductor containing material at around 800 C to form a tungsten silicide. Nickel is highly diffusive, forming nickel silicide anywhere from 350 C. In such an embodiment, if silicide  138  is created first as a tungsten silicide, silicide  140  might be subsequently created as a nickel silicide without diffusing nickel into tungsten silicide  138 . 
     Thus, different silicides may be used for different devices without additional masking steps. Additionally, this process is applicable to a plurality of devices having more than two overfill heights, with each subsequent dielectric etch exposing the next lower contact region. 
     After silicides  138  and  140  are created, contacts are formed in contact openings  134  and  136  and subsequent processing operations are performed, e.g., chemical mechanical planarization (CMP), etchback, or patterning. 
     The resulting integrated circuit chips can be distributed by the fabricator in raw wafer form (that is, as a single wafer that has multiple unpackaged chips), as a bare die, or in a packaged form. In the latter case the chip is mounted in a single chip package (such as a plastic carrier, with leads that are affixed to a motherboard or other higher level carrier) or in a multichip package (such as a ceramic carrier that has either or both surface interconnections or buried interconnections). In any case the chip is then integrated with other chips, discrete circuit elements, and/or other signal processing devices as part of either (a) an intermediate product, such as a motherboard, or (b) an end product. The end product can be any product that includes integrated circuit chips, ranging from toys and other low-end applications to advanced computer products having a display, a keyboard or other input device, and a central processor. 
     The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. 
     Having described preferred embodiments of a multi-stage silicidation process (which are intended to be illustrative and not limiting), it is noted that modifications and variations may be made by persons skilled in the art in light of the above teachings. It is therefore to be understood that changes may be made in the particular embodiments disclosed which are within the scope of the invention as outlined by the appended claims.