A Process Model for Thin Film Deposition by Sputtering: Study for Bottom Coverage of Sub-Micron Contact Holes

ABSTRACTTitanium (Ti) is widely used to improve the contact resistance with the underlying substrate in contact or via filling applications. As the critical dimensions of the electronic devices fall below 0.5 micron and the aspect ratio of the contact holes increases, it becomes more difficult to obtain a good coverage at the bottom of the contact. In our continuing effort to develop a better technology for the metallization of sub-micron liners [1, 2] using the sputtering process, we have constructed a feature scale model and have initiated an extensive study on the coverage of the contact liners. Our objective is to search for an alternative process technique to replace the current, widely-used collimated sputtering with the help of a realistic model that accounts for all important deposition phenomena such as the effect of the working pressure and the ion bombardment. Since the mean free path of the deposited atoms, particularly in a low pressure system, is comparable to the surface feature of the substrate, particle methods are more appropriate for the modeling of thin film formation phenomena and predictions of microstructures than the continuum approach. This is specially true in the case of sputter-deposition. In this paper, a simple two dimensional molecular dynamics model is used to predict the growth of the thin film. It allows us to study the effects of the physical parameters such as working pressure and ion energy as well as the influence of the geometric configuration, e.g., distance between the target and the substrate and the size of the contact hole. Simulations for long-throw/low-pressure sputtering and ionized magnetron sputtering are presented together with the experimental results for collimated sputtering.