2003 Atomic Layer Deposition Chemistry Recent Developments and Future Challenges
2003 Atomic Layer Deposition Chemistry Recent Developments and Future Challenges
2003 Atomic Layer Deposition Chemistry Recent Developments and Future Challenges
Ritala
Electronic Materials
5548 2003 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim DOI: 10.1002/anie.200301652 Angew. Chem. Int. Ed. 2003, 42, 5548 –5554
Angewandte
Atomic Layer Deposition Chemie
of four steps (Figure 1): 1) Exposure of the first precursor, saturative reaction conditions the film growth is self-limiting;
2) purge of the reaction chamber, 3) exposure of the second that is, the amount of film material deposited in each reaction
precursor, and 4) a further purge of the reaction chamber.[5] cycle is constant. The self-limiting growth mechanism brings
The growth cycles are repeated as many times as required for several advantages to ALD: 1) Film thickness depends only
on the number of reaction cycles, which makes the thickness
control accurate and simple; 2) unlike CVD, there is less need
of reactant flux homogeneity, which gives large area (large
batch and easy scale-up) capability, excellent conformality
(Figure 2) and reproducibility, and simplifies the use of solid
Figure 1. An ALD deposition cycle showing schematically the deposi- Figure 2. Cross-sectional SEM images for a 300-nm Al2O3 film (a) and
tion of TiO2 films from TiCl4 and H2O. a 14-nm TiN film (b) deposited on a patterned silicon substrate.
the desired film thickness. Depending on the process and the precursors. Separate dosing of the precursors prevents gas-
reactor being used, one cycle can take time from 0.5 s to a few phase reactions, which allows the use of highly reactive
seconds, and may deposit between 0.1 and 3 < of film precursors and gives enough time for each reaction step to
material. The cycle time depends particularly on the aggres- reach completion. This results in pure films being deposited at
siveness of the film-formation reaction. In ALD, in contrast to relatively low temperatures. The ALD processing window is
CVD, reactions with as negative a value of DG as possible are often wide, which makes the process insensitive to small
desired.[5] The film thickness obtained per cycle may depend changes in temperature and precursor flows, and allows the
on the size of the precursor molecule, because steric processing of different materials to multilayer structures in a
hindrance between large precursors limits the number of continuous process (Figure 3).[6]
molecules capable to adsorb on the surface. With small
molecules and elements as precursors, a full monolayer
growth per cycle is possible. In addition, the number of 3. Precursors
adsorption sites at the surface also affects the amount of
molecules adsorbed. ALD precursors may be gases, volatile liquids, or solids.
Ideally each exposure and purge step in ALD is complete. The vapor pressure must be high enough for effective mass
The precursor molecules chemisorb or react with the surface transportation; all solid, and some liquid precursors need to
groups saturatively, and after the formation of the chemi- be heated. Thanks to the self-limiting growth, demands for
sorbed layer no further adsorption takes place. Under these the evaporation rates to remain constant are more relaxed
Markku Leskela received a PhD in inorganic Mikko Ritala received a PhD in inorganic
chemistry in 1980 (Helsinki University of chemistry in 1994 (University of Helsinki),
Technology). He worked as both Associate and from 1995–2003 he worked as a post-
Professor (University of Oulu, 1980–86) and doctoral researcher, then as an academic
as Professor (University of Turku, 1986–90) research fellow at the same institution. He
before taking his present position as Profes- is currently Professor of inorganic materials
sor of inorganic chemistry at the University chemistry at the University of Helsinki. His
of Helsinki. His research includes thin-film research is in the area of thin-film growth
growth by various chemical methods for by atomic layer deposition and electrodepo-
micro- and optoelectronics, ranging from sition for microelectronics and other applica-
precursor synthesis to applications. He also tions. Real-time reaction mechanism studies
has an interest in coordination compound form an important part of his research. He
catalysts for olefin polymerization and oxi- has published 150 papers and holds several
dation. He has published over 370 papers patents.
and holds several patents.
Angew. Chem. Int. Ed. 2003, 42, 5548 –5554 www.angewandte.org 2003 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim 5549
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Chemie M. Leskel and M. Ritala
4. ALD in Microelectronics
5550 2003 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim www.angewandte.org Angew. Chem. Int. Ed. 2003, 42, 5548 –5554
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Atomic Layer Deposition Chemie
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Chemie M. Leskel and M. Ritala
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Atomic Layer Deposition Chemie
via the decomposition of tert-butyl groups and the elimination but as there are no other viable alternatives, ALD is and will
of isobutene and tert-butanol. Though this deposition rate is remain an important method for deposition on porous
too high for gate dielectric applications, the process may find materials and holes.
applications for ALD-grown SiO2 in spacers (Figure 4) and Selective ALD is a very attractive concept but also very
trench insulators between transistors, multilayer optical challenging. With self-assembled monolayers (SAMs) as
filters, planar waveguides, protective layers, and micro- passivation agents, ZrO2 was recently deposited selectively
electromechanical system (MEMS) devices. for Cu/ZrO2/Si capacitors.[38] The patterning of spin-coated
The deposition of tungsten films from tungsten hexa- octadecyl tetrachlorosilane (OTS) was achieved by micro-
fluoride and disilane is another example of the new smart contact printing.
chemistry.[23] Non-noble metals are difficult to prepare in
thermally activated processes, but it is possible with a suitable
combination of precursors. The new chemistry introduced for 6. The Limitations of ALD
high-k gate oxides that utilizes metal alkoxides as oxygen
sources is also showing the importance of chemistry in ALD The major limitation of ALD is its slowness; usually only a
processes.[11] fraction of a monolayer is deposited in one cycle. Typically
The use of a third component in an ALD cycle of binary deposition rates are 100–300 nm h1. Therefore it is not very
compounds opens up many possibilities. The use of bases to practical to grow micrometer-thick films by ALD. The slow
catalyze the reaction SiCl4 + 2 H2O!SiO2 + 4 HCl, and growth rate can be compensated by processing large batches
reductive pulses in the preparation of nitride films represent of substrates in one process, as is done in TFEL production. In
some existing examples.[15, 33] The third component may microelectronics, however, single-wafer processing is prefer-
introduce a new element into the film, as is in the serendip- red. Fortunately the films needed for future-generation ICs
itous case of WCxNy, where improved barrier properties and are very thin and thus the slowness of ALD is not such an
process integration were obtained. important issue.
Ternary and quaternary compounds needed for the Although the selection of film materials grown by ALD is
preparation of ferroelectric oxides are apparently the greatest wide,[5] many technologically important materials (Si, Ge,
challenge for ALD. There are two major issues: Ferroelectric Si3N4, several multicomponent oxides, certain metals) cannot
oxides contain several cations whose stoichiometry must be currently be deposited by ALD in a cost-effective way. Only a
accurately controlled. Second, for some of these elemental small number of groups have been studying new ALD
cations, such as lead, bismuth, and also to some extent precursors and processes and this has limited the develop-
strontium, there is no good ALD binary oxide process ment of the technique.
available. One solution for controlling the cation stoichiom- ALD is a chemical technique and thus there is always a
etry is to employ bimetallic complexes where the cations are risk of residues being left from the precursors. The impurity
present in the same ratio as in the desired film. SrTa2O6 has content of the films depends on the completeness of the
been deposited from such a precursor ([SrTa2(OEt)10- reactions. In typical oxide processes where metal halides or
(dmae)2]; dmae = N,N-dimethylaminoethoxide) using either alkyl compounds are used together with water as precursors,
water[34] or oxygen plasma[35] as the other precursor. Current- impurities found in the films are at the 0.1–1 atom % level.
ly, the addition of bismuth to this film is being studied with an The carrier gas is also an important source of impurities, as
aim to obtain the ferroelectric SrBi2Ta2O9. A large amount of has been exemplified, for example, with oxygen-sensitive AlN
work is still required for controlled ALD processes for films. In physical vapor deposition (PVD) methods the
ferroelectrics. environment is much cleaner due to the high vacuum used
Radical enhancement has opened new possibilities for and the lack of precursor compounds with unwanted ele-
developing ALD processes for materials which have re- ments.
mained outside the capabilities of thermally activated Because of their unique impurity background, ALD-
chemistry. Illustrative examples of this are the successful grown materials may have different properties than those
depositions of titanium, tantalum, and aluminum metals. made by PVD, for example. This has been seen in transition-
Besides materials completely new to ALD, radical enhance- metal nitride films, where small variations in composition
ment will also offer alternative, apparently lower temperature markedly affects the electrical properties.[8] Also microstruc-
routes for those materials which have so far been deposited by ture and morphology of ALD films may differ from PVD
traditional ALD processes. Radical enhancement is also films. Therefore the ALD materials have to be characterized
likely to assist in keeping precursor chemistry relatively thoroughly before use. Post-deposition treatments, particu-
simple, however, one obvious drawback of the radical larly high-temperature annealing under varied atmospheres,
enhanced processes is the need for a more complicated form an important part of this research as they may have both
reactor design. beneficial and adverse effects on purity and microstructure.
High-surface-area substrates have been a subject of ALD
studies because of their importance in heterogeneous catal-
ysis, and because they offer plenty of materials for detailed 7. Future Aspects
chemical characterization.[36] Some good results have been
obtained from depositions on porous silicon, for example.[37] Despite the achievements made over recent years, many
Slow precursor transportation makes the processes very slow, challenges still remain for the future development of ALD in
Angew. Chem. Int. Ed. 2003, 42, 5548 –5554 www.angewandte.org 2003 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim 5553
Angewandte
Chemie M. Leskel and M. Ritala
microelectronics applications. Basic research on precursor [16] P. AlKn, M. Juppo, M. Ritala, T. Sajavaara, J. Keinonen, M.
chemistry and film deposition will remain important, espe- LeskelH, J. Electrochem. Soc. 2001, 148, G566 – G571; M. Juppo,
cially when expanding the application of ALD to new P. AlKn, M. Ritala, M. LeskelH, Chem. Vap. Deposition 2001, 7,
211 – 217.
materials and devices, for example, to ferroelectric oxides
[17] M. Juppo, M. Ritala, M. LeskelH, J. Electrochem. Soc. 2000, 147,
for nonvolatile memories. Integration of the ALD processes 3377 – 3381.
and materials to the overall process flow forms another [18] M. Juppo, P. AlKn, M. Ritala, T. Sajavaara, J. Keinonen, M.
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addressed during the early stages of the process development. M. Juppo, M. Ritala, T. Sajavaara, J. Keinonen, M. LeskelH, J.
The intense research into using ALD in microelectronics Mater. Res. 2002, 17, 107 – 114.
[19] J.-S. Park, H.-S. Park, S.-W. Kang, J. Electrochem. Soc. 2002, 149,
has brought the technique wider publicity. As the general
C28 – C30.
awareness of ALD has increased, an interest in its usage in [20] H. Kim, A. J. Kellock, S. M. Rossnagel, J. Appl. Phys. 2002, 92,
other potential application areas has also increased. Such 7080 – 7085.
areas include insulator layers in magnetic write–read heads, [21] J. W. Klaus, S. J. Ferro, S. M. George, J. Electrochem. Soc. 2000,
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[23] J. W. Klaus, S. J. Ferro, S. M. George, Thin Solid Films 2000, 360,
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Dr. David Gilmer (Motorola, Austin) is thanked for Figures 4 [24] T. Aaltonen, P. AlKn, M. Ritala, M. LeskelH, Chem. Vap.
and 5. Funding from the Academy of Finland and the Finnish Deposition 2003, 9, 45 – 49; T. Aaltonen, P. AlKn, M. Ritala, M.
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2000, 18, 2016 – 2020; H. Kim, C. Cabral, Jr., C. Lavoie, S. M.
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5554 2003 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim www.angewandte.org Angew. Chem. Int. Ed. 2003, 42, 5548 –5554