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7/31/2019 Electrodeposition for Synthesis of Microsystems
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Electrodeposition for the synthesis of microsystems
This article has been downloaded from IOPscience. Please scroll down to see the full text article.
2000 J. Micromech. Microeng. 10 101
(http://iopscience.iop.org/0960-1317/10/2/301)
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J. Micromech. Microeng. 10 (2000) 101107. Printed in the UK PII: S0960-1317(00)09306-2
Electrodeposition for the synthesis ofmicrosystems
W Ruythooren, K Attenborough, S Beerten, P Merken,J Fransaer, E Beyne, C Van Hoof, J De Boeck and J P Celis
Katholieke Universiteit Leuven, Dept. Metaalkunde en Toegepaste Materiaalkunde (MTM),de Croylaan 2, B-3001 Leuven, Belgium IMEC, Dept. Microsystems, Components and Packaging (MCP), Kapeldreef 75,B-3001 Leuven, Belgium RMA, Avenue de la Renaissance 30, B-1000 Bruxelles, Belgium
Received 10 December 1999
Abstract. Electroplating is an emerging technique for the production of microsystems. Thisis due to advantages such as high rate of deposition, high resolution, high shape fidelity,simple scalability, and good compatibility with existing processes in microelectronics.Materials ranging from high-conductivity metals over soldering connections to ferromagnetscan be deposited. In this paper the basics of electroplating are reviewed and examples ofrecent applications of electroplating in the processing of microsystems are presented.
(Some figures in this article are in colour only in the electronic version; see www.iop.org)
1. Introduction
In recent years, electrodeposition has become a mature
technology for materials deposition in microelectronics
fabrication and for related applications. Whereas1015 years ago, electrodeposition was looked upon as a
dirty, low-cost method, it is now considered to be a cleantechnique while it has maintained its cost advantage over
more traditional methods such as sputtering or evaporation.
Various materials with widely diverse properties such
as composition, crystallographic orientation and grain size
can be obtained through electroplating. High-conductivitycopper or gold for interconnects and multi-chip applications,
soldering materials based on indium or tinlead required for
flip-chip, and even soft or hard magnetic materials based on
nickel, iron and cobalt are possible. In the following section,
the basic aspects of electrochemistry will be introducedfirst. Thereafter, an overview of current applications ofelectrodeposition in microelectronics production will be
given.
2. Electrodeposition process
2.1. General description
In electrodeposition, metal ions present in a solution, the
electrolyte, are reduced at the surface of an electrode to forma metal layer. This process essentially consists of:
an electrically conducting substrate such as a wafer
or another substrate; on insulating or highly-resistivesubstrates, a thin metal film (i.e. several tens of
nanometers) deposited by sputtering or other means has
to be applied first;
an electrolyte solution containing the metal ions that will
be depositedin theform of salts (e.g. CuSO4), supporting
chemicalssuch as acids or salts (e.g. H2SO4 or NaCl) and
additives (e.g. saccharine);
a counter electrode either consisting of an insolublemetal (mostly Pt, but stainless-steel is used in some
instances) or of a soluble metal with a composition
similar to the deposited material;
an electric current or voltage source for controlling the
deposition;
various peripherals for contacting the electrodes, stirring
and heating the solution, etc.
For more precise control of the deposition process, a
reference electrode can be employed.
The electrodeposition process and the most important
components are schematically represented in figure 1. Theactual geometry of the electrochemical cell used in a
practical situation can be very different depending on the
application. Cells with horizontal, vertical or slanted
substrate positioning, with stirring or pumping of the
electrolyte, with or without bubbling of air or nitrogen can
all be used.
Theefficiency of thedeposition process canbe definedas
the ratio ofthe current usedfor the reduction ofthe ionsfor the
intended deposit to the total current passed through the cell.
From thermodynamics it follows that only copper and more
noble metals can be expected to deposit with 100% efficiency
from a water-based electrolyte. For all other elements, at
least a part of the current will be consumed in the formationof hydrogen gas. Usually one wants to reduce this effect
as much as possible, not only to increase the deposition
efficiency and hence the deposition rate but also because
0960-1317/00/020101+07$30.00 2000 IOP Publishing Ltd 101
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Conduct ingsubstrate
Counterelectrode
Reference
electrode
Electrical control circuitry
Solut ion recycl ing andcondit ioning equipmentElectrolyte containing
metal and other ions
R
Figure 1. Schematic representation of a set-up forelectrochemical deposition.
the formed gas bubbles can be difficult to remove from the
sample surface and can locally hinder further deposition.
Most practical electroplating systems operate at an efficiency
of 90% or higher although in some cases it can be as low as
20%.
The deposition rate in electroplating can be determined
from Faradays law:
m = ItM
nF(1)
orh
t=
IM
nFA=
iM
nF(2)
withm themassof depositedmaterial, thecurrentefficiency
defined earlier, I the total current, t the duration of the
deposition, n the charge of the deposited ions, F Faradays
constant, h and A the thickness and area of the deposit,
the density of the deposit, M the molar mass and i the
current density. For metal deposition under typical operation
conditions, this amounts to a deposition rate of the order of
1 m min1.
Other electrochemical processes based on similar
principles as the electroplating of metals are also employed
in microelectronics fabrication. Electroless deposition of
metals, for example nickelphosphorous alloy, is mainlyused to obtain thin layers for protection of contacts.
Some materials such as aluminum and tantalum are
electrochemically oxidized in order to obtain electrically
insulating layers. These methods are outside the scope
of the present overview as is electrodeposition from non-
aqueous solutions. For some metals, e.g. aluminum [1], the
use of these types of electrolytes is the only option and the
applicability of the techniqueseems currentlyverylimited. A
further detailed description of the electrodeposition process
can be found in many text books, reference works or
dedicated papers, for example [2, 3].
2.2. Advantages of electrodeposition
Similar to more classical evaporation or sputtering
techniques, electroplating allows oneto deposit a broad range
of materials on various substrates (wafer, polymer, etc either
with a seed layer or directly on semiconductor [46]).
For microelectronics related applications, electrochem-
ical deposition has the following advantages over vacuum
techniques:
room-temperature process, thus reducing problems with
thermal stress;
low cost of equipment, no vacuum required;
high rate of deposition;
artificial material structuring such as multilayers;
conformaldeposition or depositionthrough resist masks;
great reliability for high aspect ratio structures and
excellent shape fidelity.
2.3. Possible materials and their uses
Many materials can be obtained through electroplating. The
most commonly used processes for microelectronics are
limited to deposition of metals from aqueous electrolytes.Pure metals, can usually be deposited from rather
simple plating baths. Copper is probably the easiest,
most widely used and most thoroughly studied material for
electrodeposition. Its main use in microelectronics is as low-
resistivity electrical connections. Gold and silver are used
for similar applications whereas indium is deposited as a
soldering material.
Not only single-element deposits are achievable; alloys
are also possible. Alloys are obtained from electrolytes
containing salts of the individual constituents such as in
the case of tinlead soldering materials or the soft magnetic
material Permalloy, consisting of nickel and iron.
Non-metallic elementssuchas phosphorous or boroncan
be co-deposited together with metals from baths containing
specific acids (e.g. hypo-phosphoric acid for phosphorous).
Typically, this type of deposition process has a relatively low
current efficiency, i.e. it is accompanied by a considerable
formation of hydrogen gas.
Electrodeposition allows a precise control of the
material, including its composition, its crystallographic
structure, texture and grainsize. Artificial material structures
such as multi-layers, i.e. a stacking of thin layers with
different compositions, can be obtained with relative ease.
Although metals are the most easy to obtain and by far
the most widely applied, some semiconductor materials canalso be deposited, for example gallium arsenide [7]. These
techniques maybecomeimportantfor thefabrication of opto-
electronic devices, but will not be treated here as they are of
minor relevance to microelectromechanical systems.
3. Examples
3.1. Copper for interconnects
In recent years, a new process has been introduced by IBM
to reduce the electrical resistance of the interconnects in
their chip to one-third of the values possible with aluminum
and at the same time increasing the resistance againstelectromigration [8,9]. This was achieved by implementing
electrodeposition of copper in a Damascene process. The
processing flow is presented in figure 2.
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Electrodeposition for the synthesis of microsystems
De pos i t ion o f se e d l a ye r
D e pos i t ion o f se e d l a ye r
Pat te rning of d ie lec t r ic
Pa t t e rn ing o f r e s i s t
E l e c t rode pos i t i on
Re m ova l o f re s i s tE t c h ing o f se e d l a ye r
E le c t rode pos i t i on
Planar iza t ion
D a m as cen e T h ro u g h -m a sk
Figure 2. Comparison of processing sequence for the Damasceneprocess and through-mask plating for copper interconnects.
Figure 3. Optical micrograph of microwave inductor with anelectroplated copper spiral.
Copper is deposited on a thin seed layer on top of an
oxide layer which contains trenches and vias that connect to
lower levels. Material is deposited to a thickness of about
1 m, both inside the features and on the rest of surface.
After theplating, thewafer is polished using CMP(chemical-
mechanical polishing) to remove the excess copper.
In this application, an electrodeposition process was
introduced rather than a sputtering or evaporation step since
with these latter techniques, it would be impossible to obtain
properly filled features of only a few tenths of micrometer
across andaspect ratiosof oneormore. Theelectrodeposition
process starts at the seed layer and through the use of well
chosen additives in the electrolyte, the plating process can
be adjusted to super-fill the cavities, i.e. the growth at the
bottom of the trenchesand vias proceeds more rapidly than at
the topor theedges. Such control is notpossible in sputtering
or evaporationwhere thedepositswouldsoon start to obstruct
the features and make further filling unachievable, whichwould result in voids within the interconnects.
An alternateapproach is used for interconnects on multi-
chip modules (MCM) or microwave circuitry such as the
S h a p e & w i d t h d e t e rm i n e db y r es i s t p ro cess
Dep o s i t io n w i thu n i fo rm th ick n ess
Wid th d e te rmin edb y r es i s t p ro cess Elec t ro d ep o s i t io n
Rep ro d u c t io n o f res is t l imitat ions
M in o r in c rease d u e toseed lay er e tch
Etch u n t i l su b s t r a tee x p o s e d
M ajo r in c r ease insep ara t io n w id th
S u b tra c tiv e T h ro u g h -m ask
Figure 4. Comparison of minimal feature separation for asubtractive technique and electrodeposition.
Figure 5. SEM picture of copper mushroom structures grown ontop of nanowires (height 700 nm, diameter 130 nm).
example in figure 3. In this case, the electrodeposition is
limited to the actual conductor geometry only. The required
process flow is quite different from the Damascene-based
procedure as can be seen in figure 2. Through the application
of a resist layer, only selected areas of the seed layer are
exposed to the plating solution. The thickness of the resist
should be at least equal to the final thickness that has to be
obtained for the conductors. Since the deposition process
requires electrical conductivity of the surface, it will only
take place at these uncovered places. A fairly thick copper
layer (typically 320 m) is deposited. The resist is then
removed and the seed layer etched away. Although the
electrodeposited structures are usually also exposed duringthis etching, this is of little importance since their dimensions
(some micrometers in all directions) are many times larger
than the thickness of the seed layer (typically 30100 nm).
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In addition to the general advantages of electroplating
given earlier, its application in this instance is preferable over
sputtering due to the subtractive nature of a process based on
the latter. Thecontrol over lateral dimensions andthedensity
of features that canbe obtainedbyelectrodeposition aremuch
better thanthatachievable by thenon-selectivedeposition of a
thick layer followed by an etching step (figure 4). In a similarfashion to the copper deposited for MCM interconnects,even smaller structures can be obtained. Figure 5 shows
an example of 130 nm wires deposited in resist. In this
case the deposition wasallowed to continue after the patterns
had completely filled, creating a mushroom shaped structure.This example very clearly shows the scalability of the
electrodeposition process using resist masks. Except for the
resist itself, the process is identical for both the100m sized
features forMCMapplications andfor the100 nm nanowires.
3.2. Gold
Electrodeposited goldlayers areusedon electricalconnectorsto ensure low-resistive connections and corrosion resistance
[10]. In microelectronics it is applied to bonding pads for the
same reasons. Gold can be deposited in resist patterns in a
similar fashion as copper [11].
As a related application, gold is also used as the absorber
metal in x-ray masks. Using the high shape fidelity of theplating process, masks with minimal feature sizes of 0.25m
have been demonstrated [12].
3.3. Tinlead solder
Tin-lead alloys are widely used for soldering purposes, both
for printed circuit boards and recently increasingly on thechip level. The most frequently used alloys are those close
to the eutectic composition of 40% Pb and the 95% Pb alloy
with higher melting temperature.
In microelectronics, soldering bumps are used for flip-chip bonding of circuitry integrated on wafer substrates. The
main steps of this process are briefly schematized in figure 6.Contrary to the deposition of copper discussed earlier,
the material thickness in this case is not limited to the resist
height. This can be understood by looking at the rest of
the processing sequence: the shape is not determined by the
plating step itself but by reflow of the material to ensure thespherical profile of the bumps (figure 6). Also, since quite
large volumes of material are required, the resist would haveto be impracticably thick to contain all plated material.
Vapor deposition of the tinlead material system hasbeen demonstrated by IBM and others [13] for use in the
C4 (controlled collapse chip connection) process. This
deposition is however quite difficult due to the largedifference in vapor pressures of tin and lead.
Lead can be electrodeposited quite easily, but tin needs
special care since its ions show a tendency of oxidizing
from a 2+ to a 3+ state in the solution. These Sn3+
ions are an obstacle to the plating. SnPb therefore has
traditionally been deposited from fluoroborate solutions(containing Pb(BF4)2 and Sn(BF4)2) in the printed circuit
board industry [14]. Because of environmental and safety
concerns, these fluoroborate solutions are being replaced byother types of solutions [15]. An example of the outcome of
such a successfully adopted procedure is shown in figure 7.
S u b s t r a te w i th B L Mand re s i s t mask
E lec t rop l a t ing so lde rma te r i a l
R e f l o w o f s o l d e r
Fl ip ch ip on o the rc i rcui t
F ina l geome t ry
Figure 6. Flip-chip process using electroplated soldering bumpson chip. The ball limiting metallurgy (BLM) is a specific layerstack that contains the solder material during reflow.
Figure 7. Tinlead soldering bump on a silicon substrate afterreflow.
3.4. Indium solder
Instead of a tinlead alloy, indium metal can be used as asoldering material. Actually, for certain low-temperature
applications indium is the only option since the pure
metal shows less tendency for brittle fracture and thus
improves reliability. Indium solder bumps are employed
for the flip-chip bonding of infrared detectors (embedded
in GaAs substrates) to their control circuitry (in silicon
technology). The processing sequence includes resist
patterning, electrodeposition and reflowing of the bumps
and is very similar to that presented in figure 6 for tinlead
connections.
However, as can be seen from the SEM images shown
in figure 8, the dimensions of the bumps are much smaller.
When state of the art processes are applied, the diameter forthe soldering bumps can be as small as 1025 m. Also,
since individual detectors are connected to individual parts
on the silicon chip, the density of the structures is very high
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Electrodeposition for the synthesis of microsystems
Figure 8. Indium solder bumps after reflow (top) and afterflip-chip bonding (bottom).
with the distance between the bumps being of the same order
as their sizes. As discussed earlier, such a density is not
possible with a subtractive technique (see figure 4).
3.5. Nickel-iron and other soft magnets
Soft magnetic micro-actuators or inductive components
(most notably tape or disk read-heads) can be deposited
electrochemically. Most of these applications require large
volumes of magnetic material and therefore electroplatingis the technique of choice because of its high deposition
rate and efficiency. The most widely employed material in
this class is the nickeliron alloy Permalloy (19% Fe, 81%
Ni). Controlling the deposition of this system to obtain
sufficiently narrow distribution of the composition is not
trivial (less then 1% deviation can change the magnetic
properties quite dramatically). Due to the interaction of
nickeland iron, the systemshows anomalous co-deposition
[16,17] characterized by the preferential deposition of the
less noble metal (in this case iron) over the more noble one
(nickel). Thus, even thoughtheelectrolyte contains ten times
less iron ions than it containsnickel ions, themain constituentof the deposit will still be iron. This makes monitoring of
the iron content very important, but also rather difficult due
to the relatively small quantities involved. However, good
results have been obtained and structures and inductances
withmagneticmaterial permeability of severalhundredshave
been demonstrated [1820].
Other soft magnetic materials based on nickel, iron or
cobalt or on any combination of these are also possible.
Amorphous soft magnetic alloys can also be obtained
through electrodeposition, for example cobalt containing
over 12% phosphorous. Although the current efficiency
of such a deposition system is typically rather low due to
the formation of hydrogen gas, (e.g. 3050%), the rate ofdeposition can still be high, since high current densities are
used [2123]. Very high relative permeabilities are reported
for the as-deposited material (e.g. 10 000 [24]).
102
103
104
lo
g
(co
un
ts/se
c)
4746454443424140
2theta
coni22 [5/6]*50
Figure 9. X-ray diffraction scan of a sample containing 50bilayers of 4 nm Co and 5 nm Cu. The two orders of satellitepeaks (indicated by the arrows) either side of the main CoCusuperlattice peak indicate a good compositional layering structurewithin the material.
3.6. Hard magnetic material
Recent publications indicate the possibility of achieving
hard magnetic material by electroplating. An ongoing
Brite/Euram project (a novel method for the synthesis of
microsize permanent magnets, BE97-4130) investigates a
system based on cobalt, platinum and tungsten. Another
electrodeposited permanent magnet material is CoNiMnP
[25].
As with the previous electrodeposition processes, these
materials can be deposited in structures and to substantial
thickness such that they can be used in micromechanical
systems or, for example, to introduce a biasing field in
sensors.
3.7. Multilayers
On top of the possibilities in simple metals or alloys, elec-
trodepositionallows oneto obtain synthetic microstructures
suchas multilayers [26]. Electrodeposited multilayerscan be
created by alternatingly exposing the substrate to the two (or
more) individual plating solutions (double-bath technique)or
by combining the two deposition systems into a single elec-
trolyte and choosing proper deposition conditions (single-
bath technique). Using the first method in which either the
sample is physically moved from one solution to the other
or the area to be plated is periodically contacted by the sep-arate solutions, virtually any combination of the materials
discussed earlier can be obtained: NiPSn [27], CoCu [28]
and CuNi [29].
For the single-bath method, the materials involved
have to have behaviors that are sufficiently distinct from
an electrochemical point of view. More precisely, their
deposition potential should be far enough apart; this is the
case for CoCu [5,28], AgCu [30], AuCo [30], CoPt
[31]. High-quality multilayers can be obtained through this
technique, as testified by the x-ray diffraction spectrum of
figure 9.
Most of these multilayers are used for their specific
electro-magnetic properties such as giant magneto resistance[32,33], with applications as magnetic field sensors [5]
while others find application as wear-resistant over-layers
(NiPSn).
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Figure 10. Calculated height distribution for a pattern of 28 28small circular features.
4. Remaining challenges
Although electrochemical deposition is in principle a simple
process and electroplating for micromechanical systems has
been studied extensively in the last decade, quite a few
problems remain to be tackled.
The uniformity of deposits, i.e. their thickness and,
for alloys, their composition, can be difficult to
obtain as it is influenced not only by the electrolyte
composition but also by the pattern configuration[34] (figure 10), the electrode geometry [35] and the
electrolyte hydrodynamics [11,36, 37]. Efforts to obtain
reliable numerical models are required.
During the plating process, some components of the
solution are consumed. Of course, metal ions are
deposited but also organic additives are oxidized at the
counter electrode or incorporated in the deposit. Since
theseadditives are in some instancescrucial to theproper
operation of the plating process [8, 38], it is of prime
importance to monitor their evolution. This monitoring
is a difficult task and needs further study because the
concentrations involved are very small.
The properties of electrodeposited material can differ
from those of similar material, i.e. with the same
composition, deposited by other means or manufactured
in bulk. For example, plated copper is preferable for the
Damascene process since room-temperature annealing
decreases its electrical resistance. This effect does not
occur in sputtered structures. On the other hand, for
other materials, most notably themagnetic materials, the
properties obtained are generally worse. Improvements
are certainly possible since, as stated earlier, material
characteristics such as grain size or preferred crystal
orientation can be steered through the electrodeposition
process parameters. However, for some materials this isnot yet fully understood.
While electroplating generally is a high-efficiency
process, recyclingof theelectrolyte componentsneeds to
be further investigated to further reduce the techniques
impact on theenvironment. Recycling in a closed system
can lead to an additional cost advantage over vacuum
deposition techniques.
5. Conclusions
At present, electroplating is used in the field of
microelectronics and in the production of MEMS. Most ofthe activity is generated by the replacement of the CVD
process of AlCu with the electroplating process of Cu for
low-resistivity interconnects on chips. Another important
application is the deposition of solder bumps. Soft magnetic
materials are deposited for use in inductive components and
magnetic field sensors, while the deposition of permanent
magnets is being developed. The frequency with which
new applications for the electroplating process are surfacing,
proves that the technique is very viable, and is gaining a
foothold beside PVD and CVD techniques in the productionof microelectronics and microcomponents.
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