Electrodeposition for Synthesis of Microsystems

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    Electrodeposition for the synthesis of microsystems

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    2000 J. Micromech. Microeng. 10 101

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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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    W Ruythooren et al

    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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    W Ruythooren et al

    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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    W Ruythooren et al

    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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