Patent ID: 7485556

Claim:
A method of forming a metal silicide layer on a substrate in a single process chamber, the process chamber comprising a process zone defined by a substrate support facing a metal sputtering target, a gas distributor, and a gas exhaust, the method comprising: (a) placing the substrate on the substrate support in the process zone to face the metal sputtering target; (b) sputter depositing a metal film on the substrate and siliciding substantially the entire sputter deposited metal film by: (i) heating the substrate to a silicidation temperature exceeding about 200° C.; (ii) introducing a sputtering gas into the process zone; (iii) depositing a sputtered metal film onto the heated substrate by energizing the sputtering gas by applying an electrical bias potential across the metal sputtering target and the substrate support, wherein at least a portion of the deposited sputtered metal film on the substrate forms a metal silicide layer on the substrate; and (iv) siliciding the remaining portion of the deposited sputtered metal film by maintaining the substrate at the silicidation temperature wherein step (b) is performed in the process zone of a single process chamber.