Patent Document

[0001]     This application is a Divisional of U.S. application Ser. No. 10/929,933, filed Aug. 30, 2004, which is a Divisional of U.S. application Ser. No. 09/945,553, filed Aug. 30, 2001, both of which are incorporated herein by reference. 
     
    
     FIELD OF THE INVENTION  
       [0002]     The present invention relates to semiconductor device fabrication. In particular, the present invention relates to fabrication of a metal electrode in a gate structure such as a tungsten word line, and to a process of resisting cross-contamination of volatilized metals during fabrication and field use.  
       BACKGROUND OF THE INVENTION  
       [0003]     Integrated circuit technology relies on transistors to formulate functional circuits. The complexity of these circuits requires the use of an ever-increasing number of transistors. During the manufacture of some integrated circuits, field effect transistor (FET) gate electrodes and gate electrode interconnects are etched from an electrically conductive layer that covers other circuitry. For example, in semiconductor memory circuits, wherever a word line passes over a field oxide region, it functions as a gate electrode interconnect; wherever the word line passes over a gate dielectric layer overlying an active region, the word line functions as a gate electrode.  
         [0004]     In previous integrated circuits, gate electrodes and electrode interconnects were often etched from a doped polycrystalline silicon (polysilicon) layer. However, faster operational speeds and low gate stack heights that are desirable for some applications could not be obtained using the polysilicon layer. Faster operational speeds, for example, are required for certain high-speed processor and memory circuits. Reduced gate stack heights are desirable for increasing the planarity of the integrated circuit to obtain better photolithographic resolution that is required with miniaturization. To achieve increased operational speeds and lower gate stack heights in more recent integrated circuits, it became necessary to reduce the sheet resistance of the conductive layer from which the gates and gate interconnects were formed.  
         [0005]     As semiconductor devices continued to scale to smaller dimensions, reduced resistance in the gate electrode lines of FETs also became more important. One way to reduce the resistance and the topology in a gate electrode was to use a combination of polysilicon and refractory metal films. These are known as polycide gates.  
         [0006]     One challenge in dynamic random access memory (DRAM) technology is to get the memory cell to hold a charge for longer periods of time. A longer period of time requires less frequent refreshing of the memory cell and allows for more efficient use of the memory controller for read/write/refresh demands. Leakage from the memory cell is a function of many things. There are several leakage mechanisms and pathways. For example, increased temperature will increase leakage. Impurities, traps, and defects in the junction or in the depletion width of the junction represent other leakage pathways. Further, impurities etc. in the source and drain, and defects in or near the gate will also increase leakage. Another cause of leakage includes gate-induced drain leakage (GIDL), also referred to as band-to-band tunneling. Another cause of leakage include sub-threshold leakage, which is backward tunneling of charge from the source to the drain. Another source of leakage is through the dielectric into the polysilicon, referred to as gate leakage.  
         [0007]     Three oxidation-promoting processes are used during the gate fabrication that may cause a significant amount of metal to oxidize and to volatilize and redeposit in the substrate junctions and other regions. This redeposition of metal impurities is one source for many leakage pathways. The first is a chemical vapor deposition (CVD) of silicon dioxide or silicon nitride dielectric material over the metal layer prior to the gate stack etch. This dielectric material may become the dielectric cap for the gate stack.  
         [0008]     The second oxidation-promoting process is a light thermal reoxidation. Various processes are used. They are sometimes referred to as a gate thickening oxidation (GTO), sometimes referred to as a “poly smile” oxidation, and sometimes referred to as “selective steam”. The light thermal reoxidation process is carried out to oxidize some of the polysilicon in the gate stack without causing the volumetric expansion of the metal in the gate stack by resisting the formation of a metal oxide.  
         [0009]     In the selective steam exemplary process, a wet hydrogen oxidation procedure was developed to allow the silicon to oxidize while leaving the metal such as tungsten unaffected in a post gate etch oxidation. The method was based on thermodynamic calculations which showed that at, for example, 1000° C. and a P(H2O)/P(H2) ratio (partial pressure ratio of H 2 O and H 2 ) of about 1.0×10 −05 , the equilibrium: 
 
Si+2H 2 O&lt;====&gt;SiO 2 +2H 2  
 
 tends toward oxidation of Si, and 
 
W+3H 2 O&lt;====&gt;WO 3 +3H 3  
 
 tends toward reduction of WO 3  to W. Therefore, it was possible to oxidize silicon again such that the oxidation rate of W would be reduced. However, W may volatilize during processing and recombine with the substrate in a manner that poisons active areas. 
 
         [0010]     The third oxidation-promoting process is a sidewall formation of a dielectric that becomes the gate spacer.  
         [0011]     During oxidation-promoting processes, the oxidation of silicon, including polysilicon, is self limiting to a degree. In other words, only a portion of the silicon will oxidize. Metals such as tungsten, are less self limiting. Accordingly, the tungsten may oxidize to a significant amount and even vaporize during any of these oxidation-promoting processes. Further, some metal may volatilize and recombine with portions of the semiconductor in ways that are detrimental to both device yield and field use life. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0012]     In the drawings, like reference numerals describe substantially similar components throughout the several views. Like numerals represent different orientational views of substantially similar components.  
         [0013]      FIG. 1  is an elevational cross-section of a semiconductor structure that is being fabricated in accordance with an embodiment of the present invention.  
         [0014]      FIG. 2  is an elevational cross-section of the semiconductor structure depicted in  FIG. 1  after further processing.  
         [0015]      FIG. 3  is an elevational cross-section of the semiconductor structure depicted in  FIG. 2  after further processing.  
         [0016]      FIG. 4  is an elevational cross-section of the semiconductor structure depicted in  FIG. 3  after further processing.  
         [0017]      FIG. 5  is an elevational cross-section of the semiconductor structure depicted in  FIG. 4  after further processing.  
         [0018]      FIG. 6  is a top view of a wafer or substrate containing semiconductor dies in accordance with an embodiment of the present invention.  
         [0019]      FIG. 7  is a block schematic diagram of a circuit module in accordance with an embodiment of the present invention.  
         [0020]      FIG. 8  is a block schematic diagram of a memory module in accordance with an embodiment of the present invention.  
         [0021]      FIG. 9  is a block schematic diagram of an electronic system in accordance with another embodiment the present invention.  
         [0022]      FIG. 10  is a block schematic diagram of a memory system in accordance with an embodiment of the present invention.  
         [0023]      FIG. 11  is a block schematic diagram of a computer system in accordance with an embodiment of the present invention. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0024]     The above-mentioned problems with integrated circuits and other problems are addressed by the present invention and will be understood by reading and studying the written description. Structure, system, and process embodiments are set forth herein.  
         [0025]     The following description includes terms, such as upper, lower, first, second, etc. that are used for descriptive purposes only and are not to be construed as limiting. The embodiments of an apparatus or article of the present invention described herein can be manufactured, used, or shipped in a number of positions and orientations.  
         [0026]     Reference will now be made to the drawings wherein like structures will be provided with like reference designations. In order to show the structures of the present invention most clearly, the drawings included herein are diagrammatic representations of integrated circuit structures. Thus, the actual appearance of the fabricated structures, for example in a photomicrograph, may appear different while still incorporating the essential structures of the present invention. Moreover, the drawings show only the structures necessary to understand the present invention. Additional structures known in the art have not been included to maintain the clarity of the drawings.  
         [0027]     Referring to  FIG. 1 , a semiconductor structure  10  includes a substrate  12  with a gate dielectric layer  14  and a doped polysilicon layer  16  disposed over gate dielectric layer  14 . A conductive barrier layer  18  is disposed over doped polysilicon layer  16 .  
         [0028]     Conductive barrier layer  18  is impermeable to silicon and metal atoms. In some embodiments, conductive barrier layer  18  includes a nitrided metal or metal alloy. By way of non-limiting example, conductive barrier layer  18  includes tungsten nitride (WN x ) or titanium nitride (TiN) or the like. In one embodiment, conductive barrier layer  18  is a metal nitride such as tungsten nitride W x N y , wherein x and y may sum to be either a stoichiometric ratio, or a solid solution ratio. Conductive barrier layer  18  is formed by a method such as chemical vapor deposition (CVD), by plasma-enhanced CVD (PECVD), or by physical vapor deposition (PVD). During deposition, a fluorine-containing gas is present that causes amounts of fluorine to co-deposit into conductive barrier layer  18 .  
         [0029]     In one embodiment, CVD of tungsten nitride is carried out in the presence of a fluorine-containing gas such as NF 3 . In one embodiment, the concentration of the fluorine-containing gas is NF 3  in a range from about 0.1% to about 10% by volume of the total CVD environment. In this embodiment, a tungsten nitride film forms as conductive barrier layer  18 , and the concentration of fluorine that is disposed therein is in a range from about 0.1% to about 30% by weight. In another embodiment, the concentration of fluorine that is disposed therein is in a range from about 1% to about 20%.  
         [0030]     In another embodiment, a PECVD process is carried out to form conductive barrier layer  18 . A fluorine-containing gas such as NF 3  is present in the PECVD gas feed. The process is carried out by striking a plasma and metering a tungsten and nitrogen containing gas as well as a fluorine-containing gas. In one embodiment, the concentration of fluorine-containing gas, such as NF 3  is in a range from about 0.1% to about 10% by volume of the total PECVD environment. In this embodiment, a tungsten nitride film forms as conductive barrier layer  18 , and the concentration of fluorine that is disposed therein is in a range from about 0.1% to about 30% by weight. In another embodiment, the concentration of the fluorine is in a range from about 1% to about 20%.  
         [0031]     In another embodiment, a tungsten nitride target is provided for a PVD chamber, and a PVD process is carried out to form conductive barrier layer  18 . PVD is carried out in the presence of a fluorine-containing gas. The concentration of fluorine-containing gas, such as NF 3  is in a range from about 0.1% to about 10% by volume of the total PVD environment. Typically, an inert gas such as argon (Ar) is used to act primarily as the sputtering gas. Although the exact mechanism is not set forth herein, conductive barrier layer  18  is formed with fluorine present in a range from about 0.1% to about 30% by weight. In another embodiment, fluorine is present in a range from about 1% to about 20%.  
         [0032]     In another embodiment, conductive barrier layer  18  is formed by one of CVD, PECVD, or PVD, without the presence of a fluorine-containing gas.  
         [0033]      FIG. 2  illustrates further processing. After the formation of a structure that includes gate dielectric layer  14 , doped polysilicon layer  16 , and conductive barrier layer  18 , a metal film  20  is formed, that, in combination with doped polysilicon layer  16  makes up the polycide electrode. Formation of metal film  20  is carried out by CVD, PECVD, or the like, or by PVD or the like. By way of non-limiting example, metal film  20  may comprise aluminum (Al), copper (Cu), silver (Ag), gold (Au), or the like or combinations thereof. In another embodiment, metal film  20  is a metal such as titanium (Ti), zirconium (Zr), hafnium (Hf), or the like or combinations thereof. In another embodiment, metal film  20  is a metal such as vanadium (V), tantalum (Ta), niobium (Nb), or the like or combinations thereof. Other metals for metal film  20  include nickel (Ni), cobalt (Co), palladium (Pd), platinum (Pt), or the like or combinations thereof. Other metals for metal film  20  include chromium (Cr), molybdenum (Mo), tungsten (W), or the like or combinations thereof. Other metals for metal film  20  include scandium (Sc), yttrium (Yt), lanthanum (La), cerium (Ce), or the like or combinations thereof. Other metals for metal film  20  include rhodium (Rh), osmium (Os), iridium (Ir), or the like or combinations thereof.  
         [0034]     One property embodiment is that metal film  20  has a higher melting temperature than metals that are used for subsequent metallization. Thereby, although some volatilization of metal film  20  in some instances can occur during subsequent processing, metal film  20  according to the teachings of the present invention will not melt or decompose at higher, back-end processing conditions that follow its formation. Therefore, metal film  20  will not melt during fabrication, test, and ordinary field use.  
         [0035]     Another property embodiment of metal film  20  is sufficient adhesive quality during fabrication, further processing, and field use, that metal film  20  will adhere to both conductive barrier layer  18  and to any structure that is formed over metal film. Accordingly, metals and alloys such as W, Ti, Cr, TiW, and the like are well-suited to the present invention.  
         [0036]     In one embodiment, a W metal film  20  is formed by CVD. During deposition, a fluorine-containing gas is present that causes amounts of fluorine to co-deposit into metal film  20 . In one embodiment, CVD of W is carried out in the presence of a fluorine-containing gas such as NF 3 . The concentration of NF 3  is in a range from about 0.1% to about 10% by volume of the total CVD environment. In this embodiment, a W metal film  20  forms, and the concentration of fluorine that is disposed in therein is in a range from about 0.1% to about 30% by weight. In another embodiment, the concentration of fluorine is in a range from about 1% to about 20%.  
         [0037]     In another embodiment, a PECVD process is carried out to form metal film  20 . A fluorine-containing gas such as NF 3  is present in the PECVD gas feed. The process is carried out by striking a plasma and metering a tungsten-containing gas as well as a fluorine-containing gas. The concentration of fluorine-containing gas, such as NF 3  is in a range from about 0.1% to about 10% by volume of the total PECVD environment. In this embodiment, a W metal film  20  forms, and the concentration of fluorine that is disposed in therein is in a range from about 0.1% to about 30% by weight. In one embodiment, the concentration is in the range from about 1% to about 20%.  
         [0038]     In another embodiment, a W target is provided for a PVD chamber, and a PVD process is carried out to form metal film  20 . PVD is carried out in the presence of a fluorine-containing gas. The concentration of fluorine-containing gas, such as NF 3  is in a range from about 0.1% to about 10% by volume of the total PVD environment. Metal film  20  is formed with fluorine present in a range from about 0.1% to about 30% by weight. In another embodiment, the concentration is in a range from about 1% to about 20%.  
         [0039]     In another embodiment, metal film  20  is formed by one of CVD, PECVD, or PVD, without the presence of a fluorine-containing gas.  
         [0040]     With regard to barrier layer  18  and metal film  20  in combination, a variety of composites are formed according to various embodiments. In one embodiment, a given metal is used that results in a metal compound for barrier layer  18  such as a metal nitride, a metal oxide, a metal carbide, and the like. Further, the same metal is used for metal film  20 . For example, W is used and barrier layer  18  is W x N y  and metal film  20  is W. In another embodiment, two different metals are used such as Ti and W. For example, Ti is used and barrier layer is Ti x N y  and metal film  20  is W.  
         [0041]      FIG. 3  illustrates further processing. A cap layer  22  is formed that may later act as a dielectric cap, or part of one, for a gate stack. Cap layer  22  is a silicon oxide such as silicon dioxide material such as SiO 2 , or Si x O y , where x and y sum to a stoichiometric ratio or a solid solution ratio or the like. Optionally, cap layer  22  is a nitride such as silicon nitride material, for example Si 3 N 4 , or Si x N y , where x and y sum to a stoichiometric ratio or a solid solution ratio or the like.  
         [0042]     In one embodiment, a Si 3 N 4  cap layer  22  is formed by CVD. During deposition, a fluorine-containing gas is present that causes amounts of fluorine to co-deposit into cap layer  22 . In one embodiment, CVD of a Si 3 N 4  cap layer  22  is carried out in the presence of a fluorine-containing gas such as NF 3 . The concentration of NF 3  is in a range from about 1% to about 10% by volume of the total CVD environment. In this embodiment, a Si 3 N 4  cap layer  22  forms, and the concentration of fluorine that is disposed in therein is in a range from about 1% to about 30% by weight, preferably from about 2% to about 20%.  
         [0043]     In another embodiment, a PECVD process is carried out to form Si 3 N 4  cap layer  22 . A fluorine-containing gas such as NF 3  is present in the PECVD gas feed. The process is carried out by striking a plasma and metering a silicon- and nitrogen-containing gas as well as a fluorine-containing gas. The concentration of fluorine-containing gas, such as NF 3  is in a range from about 1% to about 10% by volume of the total PECVD environment. In this embodiment, a Si 3 N 4  cap layer  22  forms, and the concentration of fluorine that is disposed in therein is in a range from about 1% to about 30% by weight, preferably from about 2% to about 20%.  
         [0044]     In another embodiment, a Si 3 N 4  target is provided for a PVD chamber, and a PVD process is carried out to form cap layer  22 . PVD is carried out in the presence of a fluorine-containing gas. The concentration of fluorine-containing gas, such as NF 3  is in a range from about 1% to about 10% by volume of the total PVD environment. Cap layer  22  is formed with fluorine present in a range from about 1% to about 30% by weight. In another embodiment, cap layer  22  is formed with fluorine present in a range from about 2% to about 20%.  
         [0045]     In another embodiment, cap layer  22  is formed by one of CVD, PECVD, or PVD, without the presence of a fluorine-containing gas.  
         [0046]      FIG. 4  illustrate further processing in which a gate stack  24  has been formed. Etching is done such as a dry anisotropic etch that may stop on gate dielectric layer  14 , although some etching thereof may occur. During etching, some of metal film  20  may volatilize, but fluorine is present in any one or all of conductive barrier layer  18 , metal film  20 , or cap layer  22 . The presence of fluorine is sufficient to cause volatilizing amounts of metal film  20  to combine with fluoride ions that is escaping from semiconductor structure  10  and to form a gas such as WF 6  that can be swept out of the processing area before significant amounts of the metal can redeposit onto substrate  12 . It is preferred to have fluorine present in a low enough concentration such that HF is not produced. Otherwise, significant etching of gate dielectric layer  14  may occur, if it is an oxide, and other oxide layers. Preferably, the presence of fluorine such as NF 3 , is in a range from about 1% to about 10% by volume. In one embodiment, the amount of fluorine is maintained low enough such that the formation of HF is prevented at concentrations that begin to etch gate dielectric layer  14 .  
         [0047]     In another processing embodiment, etching to form gate stack  24  is done in the presence of a fluorine-containing composition that is added to the etch gas mixture. Consequently, the presence of a fluorine-containing composition will cause volatilizing amounts of metal film  20  to combine with the fluorine-containing composition to form a compound such as WF 6  that can be swept out of the processing area before significant amounts of the metal can redeposit onto substrate  12 . In one embodiment, the fluorine-containing composition in the etch gas is NF 3  or the like. In any event, the composition in the etch gas will preferably have a greater affinity, either kinetic or thermodynamic or both, for combining with the volatilizing metal in metal film  20  than the substrate  12 .  
         [0048]     In summary for the etching of gate stack  24 , the presence of a fluorine-containing composition in the etch gas, in a given layer or film, or both, is used to preferentially combine with volatilizing metal. Thereby the fluorine acts to inhibit the poisoning of substrate  12  with otherwise redepositing metal that mobilizes out of metal film  20 .  
         [0049]     Further processing is carried out to treat gate stack  24 . The gate stack  24  as shown in  FIG. 4  includes an unpassivated conductive barrier layer  18  and metal film  20  and represents a starting point for the techniques described in greater detail below. The techniques can be used to help passivate the exposed surfaces of gate stack  24  so that it can be processed further in an oxidizing environment without undergoing conversion of the tungsten or other metal to a non-conductive compound.  
         [0050]      FIG. 5  illustrates this further processing. Etching of gate stack  24  typically leaves boundaries such as at gate stack side walls  26  and  28  that need treatment for better performance. A treatment process is used to smooth and/or repair the side walls  26 ,  28  of gate stack  24 . This process flow is referred to as selective steam as is known in the art. As in other processes, the selective steam process flow may cause portions of metal film  20  to volatilize and redeposit into substrate  12 . According to one embodiment, the presence of fluorine in the layers  18  and  22  or in metal film  20  may also mobilize and capture volatilizing atoms of metal film  20  to form a metal fluoride such as WF 6 . Similarly, the presence of a fluorine-containing gas in the selective steam process flow can capture and combine with volatilizing atoms of metal film  20  to form a metal fluoride such as WF 6 . During the selective steam (S/Steam) process flow, a characteristic shape  30  is formed immediately below polysilicon layer  16  in gate dielectric layer  14  that is referred to as the poly smile.  
         [0051]     In one embodiment during this treatment process flow, it is preferable to hold the concentration of the fluorine-containing gas such as NF 3 , to a range from about 1% to about 10% by volume, of the selective steam ambient in order to prevent the formation of HF in significant amounts. HF gas tends to etch oxide surfaces such as gate dielectric layer  14  where it is a gate oxide.  
         [0052]     A process example is set forth below. In this example, a 0.25 micron process is used with its design rules. By way of further reference, according to design rules, a minimum feature is part of the metric of the semiconductor structure  10  depicted in the figures. In this embodiment, the minimum feature is the width, w, of gate stack  24  when measured laterally in the figures. For example, photolithography process flows may have minimum features that are 0.25 micrometers (microns), 0.18 microns, and 0.13 microns. It is understood that the various metrics such as 0.25 microns may have distinctly different dimensions in one business entity from a comparative business entity. Accordingly, such metrics, although quantitatively called out, may differ between a given two business entities. Other minimum features that are accomplished in the future are applicable to the present invention.  
         [0053]     For this process embodiment, reference is made to  FIGS. 1-5 . A substrate  12  is provided with a gate dielectric layer  14  that is a thermal gate oxide of substrate  12 . Substrate is monocrystalline silicon with a &lt;100&gt; orientation in preparation for a metal oxide semiconductor (MOS) FET. A doped polysilicon layer  16  is formed by CVD of a silicon-bearing composition such as silane (SiH 4 ) in the presence of a dopant such as arsenic (As). Thereafter, a conductive barrier layer  18  is formed by PVD of a tungsten nitride target in the presence of about 10% NF 3  gas in addition to Ar gas.  
         [0054]     After the formation of conductive barrier layer  18 , a metal film  20  is formed by sputtering from a tungsten target in the presence of about 10% NF 3  gas in addition to Ar gas. Thereafter, a cap layer  22  is formed. Cap layer is sputtered from a Si 3 N 4  target in the presence of NF 3 .  
         [0055]     An anisotropic dry etch is carried out to form gate stack  24 . The anisotropic dry etch stops on gate dielectric layer  14  and is carried out with about 1% NF 3 .  
         [0056]     Processing is next carried out to anneal or otherwise treat the side walls  26 ,  28  of gate stack without oxidizing significant portions of metal film  20 . A selective steam process is selected from commercial vendors, and a modification is made by adding NF 3  to the process in an amount of about 1%. Further processing is carried out to make semiconductor structure  10  an active device. For example, implantation of As is carried out to form a source  32  and drain  34  that are self-aligned with gate stack  24 . A spacer layer is deposited and spacer etched over gate stack  24  according to known technique to form a spacer  36 . The presence of a fluorine-containing composition such as NF 3  is present in either or both the spacer layer deposition and the spacer etch.  
         [0057]     In other process examples, the presence of a fluorine-containing composition during processing is included or excluded, so long as at least one process in the process flow contains the presence of a fluorine-containing composition.  
         [0058]     In another process example, no deposition or oxidation process includes the presence of a fluorine-containing composition such as NF 3 , however, an NF 3  clean-up process is used after the selective steam process to scrub any re-deposited metal from metal film  20  away from substrate  12 . In another process example the NF 3  clean-up process (NF 3  scrub) is used in connection with other processes that include a fluorine-containing gas as set forth herein. Table 1 is just one set of processing combinations that is employed wherein a fluorine-containing composition is present according to the teachings of the present invention. The presence of a fluorine-containing composition is indicated by an X.  
                                             TABLE 1                           Processing Examples            Item   Ex. 1   Ex. 2   Ex. 3   Ex. 4   Ex. 5   Ex. 6               layer 18   X   X   X   X   X           film 20   X   X   X   X       X       cap 22   X   X   X       X   X       S/Steam   X   X       X   X   X       NF 3  scrub   X       X   X   X   X                  
 
         [0059]     Example 6 illustrates the beginning of a second series of process flows that omits the presence of a fluorine-containing composition during the formation of conductive barrier layer  18 . Other series are constructed wherein two processes omit the presence of a fluorine-containing composition. Yet other series are constructed wherein three processes omit the presence of a fluorine-containing composition. Similarly, another series are constructed wherein four processes omit the presence of a fluorine-containing composition.  
         [0060]     In one embodiment, the presence of fluorine in any of conductive barrier layer  18 , metal film  20 , and cap layer  22  accounts for more that about nine parts in ten for total removal of metal that volatilizes out of metal film  20  during any or all of the processes set forth herein. The remainder of metal that volatilizes out of metal film  20  is scrubbed by the presence of fluorine in a gas form such as NF 3 , during the selective steam process, or the scrub process. In any event, the combination of fluorine in one of the layers or the film, and the fluorine gas during selective steam processing or a post-oxide scrub, amounts to more that about 95% of volatilized metal being combined into a volatile gas and being swept away from substrate  12 . In another embodiment, more than about 99% of volatilized metal is combined into a volatile gas and is swept away from substrate  12 .  
         [0061]     According to another embodiment, a system is set forth that includes a semiconductor structure  10  including a substrate  12 , and a metal film  20  disposed over the substrate  12 . The metal film  20  is selected from a metal as set forth herein. The system includes a processing tool comprising a chamber. Where CVD is used, the chamber supports CVD. Where PVD is used, the chamber supports PVD. Where a combination of CVD and PVD are used, the chamber includes two tools accordingly. The system includes at least one getterer composition selected from a getterer gas and a getterer solid. The getterer composition comprises a thermodynamic or kinetic advantage over the semiconductor structure  10  for combining with the metal film  20 . In one embodiment, the getterer compound is a fluorine-containing composition, or another composition such as another halogen.  
         [0062]     Although the written description has illustrated the use of a fluorine-containing composition in virtually all examples, it is understood that other metal-reducing compositions are used, such as the other halogens, other compositions, or combinations thereof. So long as the composition acts to preferentially combine with volatilized portions of metal such as metal film  20  instead of substrate  12 , the conditions are met that reduce redeposition of the substrate  12  and/or the gate stack  24  according to the teachings of the present invention. Accordingly, a composition that combines with and reduces metal into a gaseous compound, that has either a kinetic or thermodynamic advantage over the substrate  12  for this combination, is intended according to the teachings of the present invention.  
         [0063]     In another embodiment, systems are made that include the process embodiments or the gate stack embodiments according to the teachings of the present invention. With reference to  FIG. 6 , a semiconductor die  610  is produced from a silicon wafer  600  that contains the transistor embodiment such as is depicted in  FIG. 5 . A die  610  is an individual pattern, typically rectangular, on a substrate  12  that contains circuitry to perform a specific function. A semiconductor wafer  600  will typically contain a repeated pattern of such dies  610  containing the same functionality. Die  610  may further contain additional circuitry to extend to such complex devices as a monolithic processor with multiple functionality. Die  610  is typically packaged in a protective casing (not shown) with leads extending therefrom (not shown) providing access to the circuitry of the die  610  for unilateral or bilateral communication and control. In one embodiment, die  610  is encased in a host such as a chip package (not shown) such as a chip-scale package (CSP).  
         [0064]     As shown in  FIG. 7 , two or more dies  610  at least one of which contains at least one transistor embodiment such as is depicted in  FIG. 5 , in accordance with the present invention are combined, with or without protective casing, into a host such as a circuit module  700  to enhance or extend the functionality of an individual die  610 . Circuit module  700  is a chip set that is a combination of dies  610  from  FIG. 6  representing a variety of functions, or a combination of dies  610  containing the same functionality. Some examples of a circuit module  700  include memory modules, device drivers, power modules, communication modems, processor modules and application-specific integrated circuit (ASIC) modules and include multi-layer, multi-chip modules. Circuit module  700  is a sub-component of a variety of electronic systems, such as a clock, a television, a cell phone, a personal computer, an automobile, an industrial control system, an aircraft and others. Circuit module  700  will have a variety of leads  710  extending therefrom providing unilateral or bilateral communication and control.  
         [0065]      FIG. 8  shows one embodiment of a circuit module as memory module  800  containing a structure for the transistor embodiment as is depicted in  FIG. 5 . Memory module  800  generally depicts a Single In-line Memory Module (SIMM) or Dual In-line Memory Module (DIMM). A SIMM or DIMM may generally be a printed circuit board (PCB) or other support containing a series of memory devices. While a SIMM will have a single in-line set of contacts or leads, a DIMM will have a set of leads on each side of the support with each set representing separate I/O signals. Memory module  800  acts as a host that contains multiple memory devices  810  contained on support  815 , the number depending upon the desired bus width and the desire for parity. Memory module  800  contains memory devices  810  on both sides of support  815 . Memory module  800  accepts a command signal from an external controller (not shown) on a command link  820  and provides for data input and data output on data links  830 . The command link  820  and data links  830  are connected to leads  840  extending from the support  815 . Leads  840  are shown for conceptual purposes and are not limited to the positions shown in  FIG. 8 .  
         [0066]      FIG. 9  shows another host type such as an electronic system  900  containing one or more circuit modules  700  as described above containing at least one transistor embodiment according to the teachings of the present invention. Electronic system  900  generally contains a user interface  910 . User interface  910  provides a user of the electronic system  900  with some form of control or observation of the results of the electronic system  900 . Some examples of user interface  910  include the keyboard, pointing device, monitor and printer of a personal computer; the tuning dial, display and speakers of a radio; the ignition switch and gas pedal of an automobile; and the card reader, keypad, display and currency dispenser of an automated teller machine. User interface  910  may further describe access ports provided to electronic system  900 . Access ports are used to connect an electronic system to the more tangible user interface components previously exemplified. One or more of the circuit modules  700  from  FIG. 7  is a processor providing some form of manipulation, control or direction of inputs from or outputs to user interface  910 , or of other information either preprogrammed into, or otherwise provided to, electronic system  900 . As will be apparent from the lists of examples previously given, electronic system  900  will often contain certain mechanical components (not shown) in addition to the circuit modules  700  and user interface  910 . It will be appreciated that the one or more circuit modules  700  in electronic system  900  can be replaced by a single integrated circuit. Furthermore, electronic system  900  is a sub-component of a larger electronic system.  
         [0067]      FIG. 10  shows one embodiment of an electrical device at a system level. The electronic system depicted in  FIG. 10  is a memory system  1000 . Memory system  1000  acts as a higher-level host that contains one or more memory modules  800  as described above including at least one embodiment of the transistor as set forth herein. In accordance with the present invention, memory system  1000  includes a memory controller  1010  that may also include circuitry that contains the transistor embodiment. Memory controller  1010  provides and controls a bidirectional interface between memory system  1000  and an external system bus  1020 . Memory system  1000  accepts a command signal from the external bus  1020  and relays it to the one or more memory modules  800  on a command link  1030 . Memory system  1000  provides for data input and data output between the one or more memory modules  800  and external system bus  1020  on data links  1040 .  
         [0068]      FIG. 11  shows a further embodiment of a higher-level host such as an electronic computer system  1100 . Computer system  1100  contains a processor  1110  and a memory system  1000  housed in a computer unit  1115 . Computer system  1100  is but one example of an electronic system containing another electronic system, i.e. memory system  1000 , as a sub-component. The computer system  1100  contains an input/output (I/O) circuit  1120  that is coupled to the processor  1110  and the memory system  1000 . Computer system  1100  optionally contains user interface components that are coupled to the I/O circuit  1120 . In accordance with the present invention at least one transistor embodiment is coupled to one of a plurality of I/O pads or pins  1130  of the I/O circuit  1120 . The I/O circuit  1120  may then be coupled a monitor  1140 , a printer  1150 , a bulk storage device  1160 , a keyboard  1170  and a pointing device  1180 . It will be appreciated that other components are often associated with computer system  1100  such as modems, device driver cards, additional storage devices, etc. It will further be appreciated that the processor  1110 , memory system  1000 , I/O circuit  1120  and transistor embodiments of computer system  1100  can be incorporated on a single integrated circuit. Such single package processing units reduce the communication time between the processor  1110  and the memory system  1000 .  
       CONCLUSION  
       [0069]     A gate stack is formed that includes a metal film for a lower sheet resistance and a smaller topology for use in integrated circuits. Processing of the gate stack includes the presence of a fluorine-containing composition that is co-deposited into at least one of several layers. The co-deposited fluorine acts to combine with metal in the gate stack as it volatilizes. The metal fluoride composition is swept away from the substrate and redeposition of the metal into areas of the substrate is avoided. The fluorine-containing composition can be used after a treatment such as a selective steam treatment, to scrub any metal out of the substrate that may have co-deposited. A process is also provided by which the gate stack is fabricated.  
         [0070]     With reference to a gate structure such as a DRAM transistor, impurities that mobilize during various oxidation-promoting processes, that add to cell leakage are substantially not allowed to deposit in the junction and other regions.  
         [0071]     A gate stack is formed that includes a metal film for a lower sheet resistance and a smaller topology as dictated by miniaturization needs. Processing of the gate stack includes the presence of a fluorine-containing composition that is co-deposited into at least one of several layers. The co-deposited fluorine acts to combine with metal in the gate stack as it volatilizes. The gaseous metal fluoride composition is swept away from the substrate and redeposition of the metal into areas of the substrate is avoided. Optionally or additionally, a fluorine-containing composition is used after a treatment such as a selective steam treatment, to scrub any metal out of the substrate that may have co-deposited.  
         [0072]     In one embodiment, a semiconductor structure includes a substrate with a gate dielectric layer and a doped polysilicon layer disposed over the gate dielectric layer. A conductive barrier layer is disposed over the doped polysilicon layer. The conductive barrier layer is formed by CVD, PECVD, or PVD. The conductive barrier layer is co-deposited with a halogen or the like such as fluorine.  
         [0073]     After the formation of the conductive barrier layer, a metal film is formed, that, in combination with the doped polysilicon layer makes up the polycide electrode. Formation of the metal film is carried out by CVD, PECVD, or the like, or by PVD or the like. During deposition of the metal film, a halogen-containing gas, such as a fluorine-containing gas is also be present that causes amounts of fluorine to co-deposit into the metal film. In another embodiment, the metal film is formed by one of CVD, PECVD, or PVD, without the presence of a halogen-containing gas.  
         [0074]     A cap layer is formed over the metal film that later acts as a dielectric cap, or part of one, for a gate stack. In one embodiment, a Si 3 N 4  cap layer is formed by CVD, PECVD, or PVD. During deposition, a fluorine-containing gas is present that causes amounts of fluorine to co-deposit into the cap layer. In another embodiment, cap layer  22  is formed by one of CVD, PECVD, or PVD, without the presence of a fluorine-containing gas.  
         [0075]     A gate stack is etched from the semiconductor structure. During etching, some of the metal film may volatilize, but fluorine or the like is present in any one or all of structures. The presence of fluorine is sufficient to cause volatilizing amounts of the metal film to combine with fluoride ions that are likewise escaping from the layers and to form a gas such as WF 6  that can be swept out of the processing area before significant amounts of the metal can redeposit onto the substrate.  
         [0076]     Further processing is carried out to treat the gate stack such as a selective steam oxidation. This treatment process is used to smooth and repair the side walls of the gate stack.  
         [0077]     According to another embodiment, a system is set forth that includes a semiconductor structure and a processing tool comprising a chamber. Where CVD is used, the chamber supports CVD. Where PVD is used, the chamber supports PVD. Where a combination of CVD and PVD are used, the chamber includes two tools accordingly. The system includes at least one getterer composition selected from a getterer gas and a getterer solid. The getterer composition comprises a thermodynamic or kinetic advantage over the semiconductor structure for combining with the metal film.  
         [0078]     According to another embodiment, an electrical device is set forth that includes the inventive gate stack. The electrical device is a system such as a memory module, or a processor.  
         [0079]     It will be readily understood to those skilled in the art that various other changes in the details, material, and arrangements of the parts and method stages which have been described and illustrated in order to explain the nature of this invention may be made without departing from the principles and scope of the invention as expressed in the subjoined claims.

Technology Category: 5