Highly selective etching of silicon nitride over silicon and silicon dioxide B. E. E. Kastenmeier, P. J. Matsuo, and G. S. Oehrleina) Department of Physics, The University of Albany, State University of New York, Albany, New York 12222 共Received 29 January 1999; accepted 27 August 1999兲 A highly selective dry etching process for the removal of silicon nitride 共Si3N4) layers from silicon and silicon dioxide (SiO2) is described and its mechanism examined. This new process employs a remote O2 /N2 discharge with much smaller flows of CF4 or NF3 as a fluorine source as compared to conventional Si3N4 removal processes. Etch rates of Si3N4 of more than 30 nm/min were achieved for CF4 as a source of fluorine, while simultaneously the etch rate ratio of Si3N4 to polycrystalline silicon was as high as 40, and SiO2 was not etched at all. For NF3 as a fluorine source, Si3N4 etch rates of 50 nm/min were achieved, while the etch rate ratios to polycrystalline silicon and SiO2 were approximately 100 and 70, respectively. In situ ellipsometry shows the formation of an approximately 10-nm-thick reactive layer on top of the polycrystalline silicon. This oxidized reactive layer suppresses etching reactions of the reactive gas phase species with the silicon. © 1999 American Vacuum Society. 关S0734-2101共99兲05706-1兴 I. INTRODUCTION The stripping of silicon nitride mask material after the local oxidation of silicon 共LOCOS兲 is a possible source of device damage during integrated circuit 共IC兲 fabrication. The pad oxide can suffer degradation during the overetch. Furthermore, etchants can reach the underlying Si substrate through imperfections in the pad oxide, and etch the substrate at a significant rate. This effect leaves behind craters in the substrate, and is referred to as ‘‘pitting.’’ Current dry processes used for the Si3N4 stripping step favor this undesired effect, since they typically etch Si much faster than Si3N4.1–4 Therefore, a process which etches Si3N4 selectively over both SiO2 and Si is desirable. In previous work by this group2,5 and by Blain et al.,3 the etching of Si3N4 in the afterglow of CF4 /O2 /N2 and NF3 /O2 discharges has been investigated. The flow of the fluorine source, CF4 or NF3, was kept at constant values for most experiments, and O2 and N2 were added in varying amounts. The etch rate of Si3N4 was found to be correlated to the density of nitric oxide 共NO兲 in a linear relationship for both gas mixtures. No correlation was observed between the Si3N4 etch rates and the density of atomic fluorine. The F atom concentration, determined from the polycrystalline silicon etch rate2,6 and mass spectrometry, was found to be higher by at least a factor of 20 than necessary to sustain the measured Si3N4 etch rates. We concluded that the arrival of NO is the etch rate limiting step in Si3N4 etching, and F atoms are available in abundance for Si3N4 etching. The etch rates of SiO2 共Refs. 2, 5兲 for the same parameters were found to be independent of the NO concentration, but followed the F radical density very well. The CF4 based chemistry produces the desired ratio between the etch rates of SiO2 and Si3N4. With O2 and N2 added to CF4, ratios of 10 or slightly higher could be obtained easily. The etch rate of a兲 Electronic mail: [email protected] 3179 J. Vac. Sci. Technol. A 17„6…, Nov/Dec 1999 Si3N4 typically was about 30 nm/min, that of SiO2 3 nm/min. Typical etch rate values for SiO2 and Si3N4 in the afterglow of NF3 /O2 discharges were 60 and 80 nm/min, respectively, too high to achieve selective etching of Si3N4 relative to SiO2. Etching of Si4,7 always occurred at rates much faster than those of Si3N4. Etch rates as high as 300 nm/min for CF4 /O2 /N2 and 700 nm/min for NF3 /O2 gas mixtures were measured. These high etch rates can be explained with the high F density and the spontaneous reaction of the Si surface with F atoms. The etch rate of Si varies linearly with the fluorine density.6 A decrease of the Si etch rate is consistently observed for additions of 20% or more of O2 to the CF4 or NF3 plasma. This effect is due to the oxidation of the Si surface in the presence of O and/or O2. The oxidation makes the Si surface very similar to that of SiO2 during etching, and in the limit of very high flows of O2, the etch rates of both materials become equal. Based on the above observations, a new process for the etching of Si3N4 was developed, that provides high selectivities to both SiO2 and Si. A mixture of O2 and N2 was used as the primary discharge gas, to which small amounts of a fluorine source 共CF4 or NF3) were admitted. Three mechanisms contributing to a high Si3N4 /Si selectivity are exploited by choosing an O2 /N2 based chemistry, rather than a fluorine based one. 共1兲 Decreased F atom density. The density of atomic fluorine in the reaction chamber is very low as compared to CF4 /O2 /N2 and NF3 /O2 gas mixtures. The Si etch rate decreases in the same way as the F density, since they are linearly correlated. The etch rate of Si3N4, on the other hand, should not be affected as strongly, because F is available in abundance in the conventional gas mixtures and the etching of Si3N4 in those cases is not limited by the arrival rate of F. 0734-2101/99/17„6…/3179/6/$15.00 ©1999 American Vacuum Society 3179 3180 Kastenmeier, Matsuo, and Oehrlein: Highly selective etching of silicon nitride FIG. 1. Schematic of the chemical downstream etcher used in this investigation. The gases are fed into the sapphire applicator, where a microwave discharge is ignited. The species effluent from the plasma travel through tubing of variable length and lining material to the reaction chamber. The sample is placed on the center of an electrostatic chuck. A quadrupole mass spectrometer is mounted on the chamber on top of the sample, and monochromatic ellipsometry is used to determine etch rates. 共2兲 Oxidation of the Si surface. The second mechanism that suppresses the Si etch rate is the oxidation of the Si surface in the presence of O and O2 in the gas phase. The oxidized Si surface is very inert to the attack of F atoms, therefore, the Si etch rate is significantly decreased. In addition to oxygen species, NO, which is produced in the O2 /N2 discharge, was found to contribute to the oxidation of Si surfaces.4 The surface of Si3N4 is only slightly oxidized during etching in the presence of O and O2, not enough to influence the etch rates.5,8 共3兲 Si3N4 etch rate enhancement by NO. The etch rate of Si3N4 is proportional to the density of NO. The O2 /N2 chemistry produces a significant amount of NO in its afterglow, which allows for high Si3N4 etch rates. The Si etch rate is less influenced by NO addition, and in the surface oxidation limited regime no enhancement of the etch rate is observed.4 This process also provides selectivity of Si3N4 over SiO2. The etch rate of SiO2 in the absence of ion bombardment depends only on the F density, and is expected to be smaller than the Si etch rate. In Sec. II the setup of the remote plasma etching tool and the experimental procedure are described. Subsequently, etch rates of Si3N4, poly-Si, and SiO2 are reported for both CF4 and NF3 as sources of F. Gas phase experiments 共Ar actinometry and mass spectrometry兲 are conducted to gain information about the concentration of reactive species. The surface of poly-Si suring etching is examined by ellipsometry, and the close correlation between the decrease of the etch rate and the formation of a reactive layer on the Si is demonstrated. II. EXPERIMENT The remote plasma etching tool has been described before in detail.2,4,5 Figure 1 shows a schematic of the apparatus used for the experiments. Mixtures of O2, N2, and the fluorine source 共 CF4 or NF3) are excited using an ASTEX 2.45 GHz microwave applicator with a sapphire coupling tube. The species produced in the plasma travel through a transJ. Vac. Sci. Technol. A, Vol. 17, No. 6, Nov/Dec 1999 3180 port tube to the cylindrical reaction chamber. The length of the tube was fixed at 75 cm, and the inside was lined with a Teflon liner. Samples of size 1 in. by 1 in. are glued on a 5 in. carrier wafer, which is placed on an electrostatic chuck in the reaction chamber. The materials used for this investigation are low-pressure chemical vapor deposition 共LPCVD兲 Si3N4 and thermally grown SiO2. Surface modifications of Si were studied using crystalline Si and polycrystalline Si, etch rates of silicon were determined using polycrystalline silicon. The temperature of the sample is monitored with a fluoroptic probe which contacts the backside of the sample. It was kept constant at 10 °C for all experiments. Helium at a pressure of 5 Torr was fed between the surface of the electrostatic chuck and the carrier wafer in order to obtain a good heat conduction. Etch rates are measured in situ by monochromatic ellipsometry 共wavelength 632.8 nm兲. Some analytical experiments were performed in order to gain a qualitative understanding of the mechanisms responsible for achieving the high selectivity. A fiber optic cable for optical emission experiments of the discharge was mounted on the housing of the applicator. The spectrograph used in this investigation is a 30 cm optical multichannel analyzer. A quadrupole mass spectrometer is mounted on top of the reaction chamber such that the distances from the discharge to the sample and to the orifice are the same. Some samples were moved to the surface analysis chamber through the ultrahigh vacuum 共UHV兲 wafer handling system without exposure to air. Results of similar analytical experiments on a CDE system are reported in greater detail in previous publications.2–5,7 The experiments were conducted with a sapphire applicator at 1000 W of microwave power and a chamber pressure of 600 mTorr. Flows of O2 and N2 were kept constant at 800 and 110 sccm, respectively, for most experiments. These parameters are referred to as the standard conditions. III. RESULTS AND DISCUSSION The Si3N4 etch rates were measured as a function of CF4 addition to a O2 /N2 plasma 共see top panel of Fig. 2兲. The etch rate increases linearly with the flow of CF4. The parameter for the two curves in the top panel of Fig. 2 is the amount of oxygen fed into the discharge. A lower flow of O2 共300 sccm兲 yields an etch rate about 15 nm/min higher than the flow of O2 at standard conditions 共800 sccm兲. The highest etch rates, obtained with 46 sccm of CF4, are 24 nm/min for 800 sccm of O2, and 39 nm/min for 300 sccm of O2. Nitrogen trifluoride was used as an alternative fluorine source to CF4. The plasma chemistry of NF3 is significantly different than that of CF4.5,9,10 The threshold for electron impact dissociation of NF3 is 0 eV,11,12 that of CF4 is 12.6 eV.13 This results in a higher degree of dissociation of NF3 in a discharge. In fact, in the high density microwave discharges employed for the work reported here, 100% dissociation is typically achieved.5,14 The dissociation of CF4 for 3181 Kastenmeier, Matsuo, and Oehrlein: Highly selective etching of silicon nitride 3181 FIG. 3. Etch rates of poly-Si for CF4 and NF3 as source of fluorine at standard conditions. The samples were HF dipped before the experiments to remove the native oxide layer. The initial high etch rate is suppressed as an oxygen rich reaction layer forms during etching. FIG. 2. Etch rates of Si3N4 as a function of the flow of CF4 共top panel兲 and NF3 共bottom panel兲. similar discharge parameters varies between 40% and 60%. Therefore, the production of free fluorine radicals from NF3 is higher than from CF4. Moreover, the concentration of NO in the afterglow of the discharge might be affected by the additional N atom feed. The etch rates of Si3N4 as a function of the flow of NF3 are shown in the bottom panel of Fig. 2. The measurements were performed under standard conditions, i.e., the flow of O2 was kept constant at 800 sccm. The etch rates of Si3N4 are proportional to the flow of NF3, and significantly higher if NF3 is used instead of CF4. An addition of 46 sccm of CF4, e.g., yields an etch rate of 24 nm/min, whereas the etch rate for the same flow of NF3 is twice as high 共49 nm/min兲. The etch rates of polycrystalline silicon were found to depend strongly on the initial surface conditions of the sample, and on the etch time. These etch rate variations all can be explained with the presence of a native oxide layer on the Si surface, and the formation of a reactive layer during etching. A layer of native oxide on a polycrystalline silicon film suppresses the etching almost completely. As an example, the etch rate of poly-Si at standard conditions and 30 sccm of CF4 is as low as 0.07 nm/min with the native oxide layer present. If the native oxide is removed immediately before processing by dipping the sample in HF for 3 s, the etch rate is 0.49 nm/min, a sevenfold increase. In Fig. 3 the etch rates of poly-Si are plotted as a function of time. The native oxide layer was removed before the experiments by HF dipping. Both samples were treated at standard conditions, with CF4 and NF3 as a source of fluorine. The etch rate of a ‘‘clean’’ Si surface 共no native oxide and no reactive layer兲 can be as high as 20 nm/min. As etching proceeds, the reactive layer forms on the Si and impedes etching reactions. The final etch rates are 0.50 nm/min for both CF4 and NF3. The etch rate decreases faster if CF4 is used as fluorine source. Extrapolation of the curves to the x axis, using the initial slopes, yields 12 s for CF4, and 40 s for NF3 as estiJVST A - Vacuum, Surfaces, and Films mates for the decay time. All etch rates reported in the following are ‘‘final’’ rates, measured after 300 s of etching. Figure 4 shows the etch rates of silicon as a function of CF4 共top panel兲 and NF3 addition 共bottom panel兲. Again, the parameter of the two curves in the top panel is the amount of O2 fed into the plasma. Strong variations of the etch rate with respect to the O2 flow are observed. The etch rate is significantly suppressed if 800 sccm of O2 are used. No etch rate suppression is found at a low flow 共300 sccm兲 of O2. At 30 sccm of CF4, for example, the etch rate for 300 sccm of O2 is 19 times larger than that for 800 sccm. The Si etch rate is proportional to the flow of NF3 at small flows up to 20 sccm. At higher NF3 flows, the etch rate assumes a plateau value at 0.5 nm/min. The etch rates of silicon dioxide are plotted in Fig. 5. The top panel shows etch rates when CF4 is used as a fluorine source. Etching occurs only at the low flow of O2 共300 FIG. 4. Etch rate of poly-Si vs the flow of CF4 共top panel兲 and NF3 共bottom panel兲. The ellipsometric determination of an etch rate for 300 sccm of O2 and flows of CF4 higher than 30 sccm was not possible, probably due to the formation of roughness on top of the poly-Si. 3182 Kastenmeier, Matsuo, and Oehrlein: Highly selective etching of silicon nitride FIG. 5. Etch rates of SiO2. At the high O2 flow with CF4 added, the etch rates were too small to be detected by ellipsometry 共⬍0.05 nm/min兲. sccm兲, and etch rates never exceed 1 nm/min. The etch rates at 800 sccm of O2 were too small to be detected by ellipsometry 共⬍0.5 nm/min兲. In the bottom panel, the etch rates for 800 sccm of O2 and NF3 as a fluorine source are shown. The etch rates increase linearly for NF3 flows up to 30 sccm, and then level out at 0.8 nm/min. The Si3N4 /Si etch rate ratio obtained from Fig. 2 and Fig. 4 is shown in Fig. 6. If CF4 is used as a fluorine source 共top panel兲, the highest selectivity is achieved at the high O2 flow and intermediate flows of CF4. At these conditions, the selectivity assumes a peak value of around 40. The selectivity for the low O2 flow is much less due to the higher Si etch rates. If NF3 is used 共bottom panel兲, the selectivity increases 3182 FIG. 7. Ratio of the Si3N4 and SiO2 etch rates, determined from the data shown in Fig. 2 and Fig. 5. The curve for the high O2 flow in the top panel is missing, since the selectivity at these conditions is extremely high. with increasing flow of NF3. A selectivity value of 100 is reached at standard conditions. In Fig. 7, the ratio of the Si3N4 and SiO2 etch rates is shown. These data are obtained from Fig. 2 and Fig. 5. In the case of CF4 as fluorine source 共top panel兲, the curve for the high O2 flow is missing. These values are extremely high 共⬎500 or infinity兲 due to the unmeasurably small SiO2 etch rates at these conditions. The selectivities for NF3 as a fluorine source 共bottom panel兲 are at around 60 for intermediate flows of NF3, and have an increasing tendency at higher flows. The selectivities reported here are improved significantly as compared to those obtained in earlier work. In CF4 based etching of Si3N4, a typical selectivity to the underlying pad oxide of 10 is achieved. For a NF3 based chemistry, which is predominantly used for chamber cleaning after deposition processes, this value is less than half as big. In both chemistries, Si is etched at a significantly faster rate than Si3N4. In Table I, the Si3N4 etch rates and selectivities to SiO2 and Si are summarized for these processes, together with the data presented above. Several experiments were performed to investigate quantitatively the importance of the three mechanisms mentioned above for achieving high Si3N4 /SiO2 and Si3N4 /Si selectivities while maintaining a high Si3N4 etch rate. As described in previous work,2,5 argon actinometry and quadrupole mass TABLE I. Typical values of the Si3N4 etch rate and the selectivities to SiO2 and Si. See Refs. 2 and 4 for the work on CF4 /O2 /N2, and Refs. 5 and 7 for NF3 /O2. CF4 /O2 /N2 NF3 /O2 O2 /N2 /CF4 O2 /N2 /NF3 FIG. 6. Ratio of the Si3N4 and Si etch rates, determined from the data shown in Fig. 2 and Fig. 4. J. Vac. Sci. Technol. A, Vol. 17, No. 6, Nov/Dec 1999 Si3N4 etch rate 共nm/min兲 Sel Si3N4 /SiO2 Sel. Si3N4 /Si 30 10 0.1–0.6 80..350 0.7–4 0.1–0.8 10..20 ⬎500 30 30..50 60 80–100 3183 Kastenmeier, Matsuo, and Oehrlein: Highly selective etching of silicon nitride 3183 FIG. 9. Signal intensity of the NO⫹ peak at amu 30 in the reaction chamber. FIG. 8. Variation of the F atom concentration in the discharge region, as determined by Ar actinometry. See the text for the parameters used for this measurement. spectrometry were used to measure the change of the concentration of species relevant for etching. For the actinometry measurements,15,16 argon at a constant flow rate of 60 sccm was injected into the discharge. Figure 8 shows the intensity ratio of the F emission at 703.7 nm and the Ar line at 811 nm. This ratio is proportional to the F atom density in the discharge. The top panel shows the ratio for CF4 , the bottom panel for NF3 as a source of fluorine. The ratio is approximately 4 times higher if NF3 is used as compared to CF4 , indicating a higher F atom concentration in the case of NF3 . This is consistent with the observation that NF3 is dissociated to a higher degree than CF4 in microwave discharges.5 For the present experiments, mass spectrometry measurements of the NF⫹ 3 peak 共amu 71兲 for plasma-on and plasma-off states show the complete destruction of NF3 . The corresponding measurement of the CF⫹ 3 intensity 共amu 69兲 suggests a dissociation of the CF4 of about 20%–30%, if it is assumed that the contribution of CF3 radicals produced in the discharge of the signal intensity of the peak at amu 69 is negligible. A significant amount of NO is present in the reaction chamber during the experiments reported here. The intensity of the NO⫹ peak at amu 30 is shown in Fig. 9. In the case of CF4 共top panel兲, the signal intensity decreases by almost 50% as a small amount of CF4 共15 sccm兲 is added to the O2 /N2 discharge, and then decreases further as more CF4 is injected. The same initial decrease is observed for NF3 added to O2 /N2 共bottom panel兲, but then, in contrast to the CF4 case, the NO density increases as more NF3 is injected. The proportionality of both the actinometrically determined F density in the discharge and the Si3N4 etch rate with the amount of F-containing gas added suggests that the Si3N4 etch rate is limited by the amount of F atoms available for etching reactions. No correlation is observed between the NO density in the reaction chamber and the Si3N4 etch rate. JVST A - Vacuum, Surfaces, and Films This is in contrast to CF4 and NF3 based processes, in which small amounts of O2 and/or N2 are added to the F-containing gas. In these cases, F atoms are available in abundance, and the Si3N4 etch rates were found to be limited by the NO density.2,5 As mentioned above, a thick reactive layer on top of the Si surface inhibits etching reactions. The formation of this layer was monitored in situ during the etching by monochromatic ellipsometry. Figure 10 shows the time evolution of FIG. 10. Evolution of the ellipsometric variables ⌿ and ⌬ during the etching of a film of polycrystalline silicon 共total thickness 250 nm兲 on a SiO2 layer 共100 nm兲 on a Si共100兲 substrate. The experiments were performed under standard conditions, with addition of 30 sccm of CF4 共top panel兲 or 30 sccm of NF3 共bottom panel兲. The time interval between two data points is 1.1 s. Simulations of ⌿/⌬ for different reactive layer thickness 共0, 10, and 12.5 nm兲 on top of the poly-Si are included. An increase in ⌬ is equivalent to the removal of the poly-Si and increase in ⌿ means the growth of the oxidized reactive layer. 3184 Kastenmeier, Matsuo, and Oehrlein: Highly selective etching of silicon nitride the ellipsometric variables ⌿ and ⌬ as a function of time 共dotted curves, top panel for CF4 , bottom panel for NF3 ). A multilayer stack consisting of poly-Si 共total thickness 250 nm兲 on top of SiO2 共100 nm兲 on a Si共100兲 substrate was etched. The lines in Fig. 10 show calculations of the ellipsometric variables ⌿ and ⌬. These can be calculated by assuming values for the thickness and the optical parameters of each layer of the stack. Also the reactive layer can be included in those calculations as a film of a certain thickness on top of the poly-Si. In Fig. 10, the results of these calculations for three different thicknesses of the reactive layer 共0, 10, and 12.5 nm兲 are included. Etching of the poly-Si corresponds to an increase of the value of ⌬. At the same time, information about the reactive layer thickness is obtained from ⌿. An increase of ⌿ means an increase of the reactive layer thickness. The top panel of Fig. 10 shows the etching of polycrystalline Si and formation of the reactive layer under standard conditions with 30 sccm of CF4 added. Immediately after the plasma is ignited and tuned 共‘‘start’’兲 the reactive layer grows at a considerable rate, and Si is removed at the same time. The time interval between two measurement points is 1.1 s. The reactive layer assumes a steady state thickness of approximately 10 nm. At this thickness value the etch rate of Si is slowed down to 0.4 nm/min. At the moment the discharge is terminated 共‘‘end’’兲, the overlayer thickness has increased to about 12.5 nm. The etch time from start to end was 475 s, and 16.7 nm of Si was removed in that time. After termination of the discharge 共‘‘postplasma’’兲, more surface modifications occurred. NF3 was used instead of CF4 for the experiment shown in the bottom panel. As in the case of CF4 , growth of the reactive layer and poly-Si etching occur simultaneously. However, some significant differences are observed: The formation of the reactive layer happens at a slower rate than in the case of CF4 etching, and the reactive layer does not achieve a steady state thickness, but continues to grow. Also the postplasma modifications show a different trend. IV. CONCLUSIONS A novel remote plasma chemical dry etching 共CDE兲 process which enables selective etching of Si3N4 over silicon and SiO2 with an etch rate ratio greater than 30:1 has been demonstrated. It uses high flows of O2 and N2, and relatively small additions of CF4 and NF3 as a source of fluorine. For the experiments reported here, the silicon nitride etch rate is limited by the flux of F atoms to the surface. Nitric oxide is available in abundance and does not influence the Si3N4 etch rate. This is the inverse of processes in which small amounts of O2 and/or N2 are added to a CF4 or NF3 discharge. The significantly decreased F atom density, especially for the case of CF4 as a fluorine source, is not sufficient to etch Si3N4 with a high selectivity over silicon. Also the Si3N4 etch rate boosted by the high NO density in the chamber is not sufficient for a high etch rate ratio. From the data presented J. Vac. Sci. Technol. A, Vol. 17, No. 6, Nov/Dec 1999 3184 above, it can be concluded that the formation of an etchinhibiting reactive layer on top of the Si is the dominant mechanism for achieving a high Si3N4 etch rate ratio. The etching of the virgin silicon surface proceeds at a rate of approximately 20 nm/min. In situ ellipsometry shows the formation of a reactive layer on top of the polycrystalline silicon during the etch process within a matter of seconds. The etch rate of silicon is decreased to a level comparable to that of SiO2 after the reactive layer has formed. Finally, the authors would like to suggest that imperfect gate oxides can potentially be improved by the process investigated here. The reactive layer that forms on top of the Si during etching is highly oxidized with some F content, and thus similar to the gate oxide. It is possible that the Si underneath voids or imperfections in the gate oxide are oxidized during the overetch period after the Si3N4 removal, thus improving the electrical properties of the gate. ACKNOWLEDGMENTS The authors would like to thank Matt Blain, Gary Powell, John Langan, Rob Ellefson, and Lou Fries for their support and fruitful discussions. Marc Schaepkens, Theo Standaert, and Christian Völker are thanked for their helpful ideas and technical assistance. We would like to acknowledge Matrix Integrated Systems, Sandia National Laboratories, Air Products and Chemicals, and Leybold Inficon for financial support of this study. 1 N. Hayasaka, H. Okano, and Y. Horiike, Solid State Technol. 31, 127 共1988兲. 2 B. E. 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