(Invited) Epitaxial Growth of Ge/III-V Films and Hetero-Layer Lift-off for Ultra-Thin GeOI Fabrication
Authors: Maeda Tatsuro , Irisawa Toshifumi , Ishii Hiroyuki , Chang Wen Hsin 
Published: December 2020

Monolithic 3D (M3D) integration has been thought of as an attractive idea to realize multi-functional heterogeneous integration devices. M3D integration enables us to combine logic devices with different functional devices such as memory, sensor, or optics to create extremely compact and efficient system-on-chips. Ge and III-V compound semiconductors are expected to be implemented as high mobility channel materials and optical components which cannot be realized with Si. The layer transfer technique with low processing temperature has great potential for stacking non-lattice-matched crystalline materials for M3D ICs. Here, we discuss the layer transfer technology utilizing high quality epitaxial growth, low-temperature direct bonding and advanced epitaxial lift-off (ELO) process, which reveals the applicability of transferred layers for heterogeneous integration.

The low temperature ELO process is essential for realizing reliable layer transfer with different materials because the process is almost free from the issues of thermal expansion mismatch. Process flow of GaAs or Ge layer transfer with ELO process is described in Fig. 1. First of all, a lattice-matched single crystal GaAs or Ge layer is epitaxially grown on GaAs substrate with an AlAs release layer by MOCVD. Subsequently, Al2O3 layer is deposited on the epitaxial layer by atomic layer deposition (ALD). ALD Al2O3 layer serves as the buried oxide (BOX) and the passivation layer for Ge or GaAs surface. Then, Ge or GaAs layer is patterned using photolithography. The patterned GaAs or Ge/AlAs/GaAs donor wafer is then bonded on host substrate by direct bonding technique with wet activation process. Finally, the epitaxial GaAs or Ge layer is transferred on host substrates by splitting GaAs donor wafer from AlAs layer with HCl side etching thanks to extremely high etching selectivity. Note that the fabrication of patterned transfer layer is effective in shortening the required time of ELO process. In this ELO process, the thickness of a transferred layer can be control by epitaxial layer thickness. After the layer transfer process, the released donor GaAs wafer can be reclaimed and reused for the subsequent re-epitaxial growth to reduce the process cost.

Figs. 2 (a) and (b) show cross-sectional SEM and TEM images of fabricated GeOI substrate with different BOX structures. Ge pattern edge shows no peeling from SiO2(100nm)/Si substrate, indicating strong bonding strength at the pattern edge. In Fig. 2 (b), the bonding interface is clearly observed at Al2O3(5nm)/SiO2(50nm) interface formed by the wet activation process. The bonding interface exhibits very smooth and no defect. There is no observable defect in transferred Ge layer, suggesting dislocation density is below TEM detection limit. Compared to Smart-CutTM technique, ELO process has significant advantages in terms of crystal quality, thickness control and the surface flatness thanks to totally low temperature processing.

To reduce wafer-scale thickness variation, etching stopper (ES) technique with high etching selectivity is quite useful. As a donor wafer, we prepare Ge active layer (20nm)/SiGe ES layer (5nm)/Ge buffer layer/AlAs/GaAs structures. Here, the SiGe layer serves as ES against the etching of Ge buffer layer to control the final GeOI thickness and attain the wafer-scale thickness uniformity. In addition, Si passivation on Ge surface was performed during initial epitaxial growth of donor wafer since Si passivation was proved to be effective in reducing interfacial trap density (D
it) between Ge and oxide. After ELO process, Ge buffer layer /SiGe ES layer/Ge active layer / Al2O3 /SiO2/Si heterostructure was obtained. Then, the top Ge buffer layer was removed in HCl/H2O2 solution. We found the etching selectivity was more than 30 between Ge and SiGe layer, which is high enough to yield very smooth SiGe surface. Finally, SiGe layer was removed by TMAH preferentially.

Further conformal thinning of Ge active layer was performed by the cyclic dry oxidation/wet digital etching (DE) at room temperature. In addition to thickness control with the etching rate of about 0.8 nm/cycle, it is found that dozens digital etching (DDE) process is effective for reducing Ge surface roughness. Finally, UTB GeOI substrates with high crystal quality down to 3 nm have been successfully fabricated through SiGe ES and DDE processes. Ultra-smooth GeOI surface with reduced thickness fluctuation was confirmed after DDE by TEM cross-sectional images, resulting in significant improvement of device performances.

Figure 1