ic technology- crystal structure and crystal growth

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IC TECHNOLOGY INTRODUCTION TO IC TECHNOLOGY By: Kritica Sharma Assistant Professor (ECE)

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Page 1: Ic technology- Crystal structure and Crystal growth

IC TECHNOLOGYINTRODUCTION

TO IC TECHNOLOGY

By:Kritica Sharma

Assistant Professor (ECE)

Page 2: Ic technology- Crystal structure and Crystal growth

CONTENTS

2

Understanding IC Moore’s law Semiconductor Substrate Crystal defects Czochralski Growth Float Zone Wafer Preparation- Silicon Shaping, Etching

and Polishing, Chemical cleaning.

Page 3: Ic technology- Crystal structure and Crystal growth

UNDERSTANDING IC Definition: An integrated circuit (IC), sometimes

called a chip or microchip, is a semiconductor wafer on which thousands or millions of tiny resistors, capacitors, and transistors are fabricated.

An IC can function as an amplifier, oscillator, timer, counter, computer memory, or microprocessor.

Page 4: Ic technology- Crystal structure and Crystal growth

What advantages do ICs have over discrete components?

Size: Sub-micron vs. millimeter/centimeter. Speed and Power: Smaller size of IC components yields

higher speed and lower power consumption due to smaller parasitic resistances, capacitances and inductances.

Switching between ‘0’ and ‘1’ much faster on chip than between chips.

Lower power consumption => less heat => cheaper power supplies => reduced system cost.

Integrated circuit manufacturing is versatile. Simply change the mask to change the design.

However, designing the layout (changing the masks) is usually the most time consuming task in IC design.

Page 5: Ic technology- Crystal structure and Crystal growth

IC MARKET

The semiconductor industry is approaching $300B/yr in sales

Page 6: Ic technology- Crystal structure and Crystal growth

IC TECHNOLOGY INVENTION Early developments of the Integrated

Circuit (IC) go back to 1949. German engineer Werner Jacobi filed a

patent for an IC like semiconductor amplifying device showing five transistors on a common substrate in a 2-stage amplifier arrangement.

Jacobi disclosed small cheap of hearing aids.

Page 7: Ic technology- Crystal structure and Crystal growth

Inventor Year Circuit Remark

Fleming 1904

1906

Vacuum tube diodeVacuum triode

Large expensive, power-hungry, unreliable

William Shockley(Bell Labs)

1945 Semiconductor replacingvacuum tube

Bardeen andBrattain andShockley(Bell labs)

1947 Point Contact transferresistance device “BJT”

Driving factor of growthof the VLSI technology

Werner Jacobi(Siemens AG)

1949 1st IC containingamplifying Device2stage amplifier

No commercial usereported

Shockley 1951 Junction Transistor “Practical form oftransistor”

Jack Kilby(Texas Instruments)

July 1958 Integrated Circuits F/FWith 2-T Germaniumslice and gold wires

Father of IC design

Page 8: Ic technology- Crystal structure and Crystal growth

Inventor Year Circuit Remark

NoyceFairchildSemiconductor

Dec. 1958 IntegratedCircuitsSilicon

“The Mayor ofSilicon Valley”

KahngBell Lab

1960 First MOSFET Start of new era forsemiconductorindustry

FairchildSemiconductorAnd Texas

1961 First CommercialIC

Frank Wanlass(Fairchild Semiconductor)

1963 CMOS

Federico Faggin(Fairchild Semiconductor)

1968 Silicon gate ICtechnology

Later Joined Intel tolead first CPU Intel4004 in 19702300 T on 9mm2

ZarlinkSemiconductors

Recently M2A capsule forendoscopy

take photographs ofdigestive tract 2/sec.

Page 9: Ic technology- Crystal structure and Crystal growth

MOORE’S LAW Gordon E. Moore - Chairman Emeritus of Intel

Corporation 1965 - observed trends in industry - of transistors on ICs vs. release dates:

Noticed number of transistors doubling with release of each new IC generation release dates (separate generations) were all 18-24 months apart

Moore’s Law: “The number of transistors on an integrated circuit will double every 18 months”

The level of integration of silicon technology as measured in terms of number of devices per IC Semiconductor industry has followed this prediction with surprising accuracy.

Page 10: Ic technology- Crystal structure and Crystal growth

SEMICONDUCTOR SUBSTRATE Semiconductor-A semiconductor is a substance,

usually a solid chemical element or compound, that can conduct electricity under some conditions but not others, making it a good medium for the control of electrical current.

Substrate-A wafer, also called a slice or substrate, is a thin slice of semiconductor material, such as a crystalline silicon, used in electronics for the fabrication of integrated circuits and in photovoltaics for conventional, wafer-based solar cells.

Page 11: Ic technology- Crystal structure and Crystal growth

CRYSTALLOGRAPHY AND CRYSTAL STRUCTURE A crystal structure is a unique arrangement of atoms

in a crystal. A crystal structure is composed of a unit cell, a set of atoms arranged in a particular way; which is periodically repeated in three dimensions on a lattice.

Crystals are described by their most basic structural element: the unit cell. A crystal is an array of these cells, repeated in a very regular manner over three dimensions. The unit cell of have cubic symmetry with each edge of the unit cell being the same length.

Page 12: Ic technology- Crystal structure and Crystal growth

CRYSTAL STRUCTURE Lattice + Basis = Crystal structure Lattice: Atomic arrangements in crystalline solids can be

described with respect to a network of lines in three dimensions.

The intersections of the lines are called “lattice sites” (or lattice points). Each lattice site has the same environment in the same direction• “Basis” is the atom placed at each lattice site.• Unit cell: small repeating entity of the atomic structure.

The basic building block of the crystal structure.

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METALLIC CRYSTAL STRUCTURES

Unit cell: small repeating entity of the atomic structure. The basic building block of the crystal structure. It defines the entire crystal structure with the atom positions within .

Page 14: Ic technology- Crystal structure and Crystal growth

MILLER INDICES OF CRYSTAL PLANES

Z

X

Y

(100)

Z

X

Y

(110)

Z

X

Y

(111)

Page 15: Ic technology- Crystal structure and Crystal growth

CRYSTAL ORIENTATION• The processing characteristics and some material properties

of silicon wafers depend on its orientation. The <111> planes have the highest density of atoms on the surface, so crystals grow most easily on these planes and oxidation occurs at a higher pace when compared to other crystal planes.

• Traditionally, bipolar devices are fabricated in <111> oriented crystals whereas <100> materials are preferred for MOS devices.

Page 16: Ic technology- Crystal structure and Crystal growth

TYPES OF CRYSTAL STRUCTUREThe three common types of cubic crystals are: 1. Simple cube2. Body centered cube3. Face centered cube

Page 17: Ic technology- Crystal structure and Crystal growth

SIMPLE CUBIC CELL Simple cubic unit cell: In this case one atom or ion

lies at each corner of the cube. Since only 1/8 of each corner sphere lies within the unit cell hence simple cubic unit cell contains a total (1/8) 8 =1, atom or ion. The volume occupied by the particles in simple cubic unit cell is 52.4% and open space in this cell is 47.6%.

Page 18: Ic technology- Crystal structure and Crystal growth

UNIT CELL IN SIMPLE CUBIC (SC) 3-D STRUCTURE Very few crystals exhibit

this structure.

Eg: Polonium (for a narrow range of

temperature)

Unit cell

Page 19: Ic technology- Crystal structure and Crystal growth

CONTD.. Simple cubic cell: • Rare due to poor packing (only Po has this structure) • Close-packed directions are cube edges. • Coordination = 6 (nearest neighbours)

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Page 21: Ic technology- Crystal structure and Crystal growth

BODY CENTERED CUBIC CELL  Body centred cubic unit cell: In this case one atom

or ion lies at each comer of the cube and one atom (or ion) lies at the centre of the cube (unshared atom or ion).

Thus the contribution of the 8 corners is (1 / 8 ) X 8 = 1, while that of the body centred (unshared atom) is 1 in the unit cell.

The hard spheres touch one another along cube diagonal ⇒ the cube edge length, a= 4R/√3.

Page 22: Ic technology- Crystal structure and Crystal growth

CONTD.. The coordination number, CN = 8. Number of atoms per unit cell, n = 2. Center atom shared by no other cells: 1 x 1 = 1. 8 corner atoms shared by eight cells: 8 x 1/8 = 1. Atomic packing factor, APF = 0.68. Corner and center atoms are equivalent

Page 23: Ic technology- Crystal structure and Crystal growth

GEOMETRY OF BCC STRUCTURE Coordination No. 8 No of atom per unit cell : 8*1/8 +1=2

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Page 25: Ic technology- Crystal structure and Crystal growth

FACE CENTERED CUBIC CELL  In this case one atom or ion lies at each corner of the

cube and one atom or ion lies at the centre of each face of the cube. It may be noted that only 1/2 of each face sphere lies within the unit cell and there are six such faces. The total contribution of 8 comers is (1 / 8 ) x 8 =1 while that of 6-face-centred atoms is (1 / 2)×6 = 3 in the unit cell. Hence total number of atoms per unit cell is 1 + 3 = 4 atoms (or ions).

Page 26: Ic technology- Crystal structure and Crystal growth

CONTD,.. Atoms are located at each of the corners and on the

centers of all the faces of cubic unit cell . Cu, Al, Ag, Au have this crystal structure n fcc is 74% and open space is 26%.

The hard spheres or ion cores touch one another across a face diagonal ⇒ the cube edge length, a= 2R√2 .

The coordination number, CN = the number of closest neighbours to which an atom is bonded = number of touching atoms, CN = 12 .

Page 27: Ic technology- Crystal structure and Crystal growth

CONTD.. Number of atoms per unit cell, n = 4. (For an atom

that is shared with m adjacent unit cells, we only count a fraction of the atom, 1/m). In FCC unit cell we have: 6 face atoms shared by two cells: 6 x 1/2 = 3 8 corner atoms shared by eight cells: 8 x 1/8 = 1 .

Atomic packing factor, APF = fraction of volume occupied by hard spheres = (Sum of atomic volumes)/(Volume of cell) = 0.74 (maximum possible)

Page 28: Ic technology- Crystal structure and Crystal growth

SILICON UNIT CELL: FCC DIAMOND STRUCTURE OR ZINCBLENDE OR SPHALERITE STRUCTURE

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Page 30: Ic technology- Crystal structure and Crystal growth

POLYCRYSTALLINE AND MONOCRYSTALLINE STRUCTURES

Polycrystalline structure Monocrystalline structure

Page 31: Ic technology- Crystal structure and Crystal growth

AXES OF ORIENTATION FOR UNIT CELLS

Z

X

Y

1

1

1

0

Page 32: Ic technology- Crystal structure and Crystal growth

COORDINATES FOR ZINCBLENDE CUBIC STRUCTURE( DIAMOND) Coordination number (number of neighboring atoms) is 4. Distance between two neighboring atoms is (√3/4)a, where

a is lattice constant. For Si it is =2.351 angstrom.

(1/4,1/4,1/4)

(1/4,3/4,1/4)

Page 33: Ic technology- Crystal structure and Crystal growth

CRYSTAL DEFECTSA crystal defect (microdefect) is any interruption in the repetitive nature of the unit cell crystal structure. These may occur during manufacturing process.

Three general types of crystal defects in silicon:1. Point defects -Localized crystal defect at

the atomic level2. Dislocations - Displaced unit cells3. Planar or - Defects in crystal structure area defects

Page 34: Ic technology- Crystal structure and Crystal growth

CRYSTAL DEFECTS

A perfect crystal is an idealization; there is no such thing in nature. Atom arrangements in real materials do not follow perfect crystalline patterns. Nonetheless, most of the materials that are useful in engineering are crystalline to a very good approximation.

Crystalline solids exhibit a periodic crystal structure. The positions of atoms or molecules occur on repeating fixed distances, determined by the unit cell parameters. However, the arrangement of atoms or molecules in most crystalline materials is not perfect. The regular patterns are interrupted by crystallographic defects

Page 35: Ic technology- Crystal structure and Crystal growth

POINT DEFECTS

Page 36: Ic technology- Crystal structure and Crystal growth

The three basic classes of defects in crystals:

• Point defects - atoms missing or in irregular places in the lattice (lattice vacancies, substitutional and interstitial impurities, self-interstitials).

• Linear defects - groups of atoms in irregular positions (e.g. screw and edge dislocations).

• Planar defects – the interfaces between homogeneous regions of the material (grain boundaries, stacking faults, external surfaces).

Page 37: Ic technology- Crystal structure and Crystal growth

POINT DEFECTS A perfect crystal with regular arrangement of atoms

can not exist. There are always defects, and the most common defects are point defects. This is especially true at high temperatures when atoms are frequently and randomly change their positions leaving behind empty lattice sites, called vacancies.

How many vacancies are there: The higher is the temperature, more often atoms are jumping from one equilibrium position to another and larger number of vacancies can be found in a crystal.

Page 38: Ic technology- Crystal structure and Crystal growth

CONTD..

The number of vacancies, Nv, increases exponentially with the absolute temperature, T, and can be estimated using the equation (Boltzmann Distribution): where Ns is the number of regular lattice sites, k is the Boltzmann constant, and Ev is the energy needed to form a vacant lattice site in a perfect crystal.

TkENNB

vsv

Page 39: Ic technology- Crystal structure and Crystal growth

TYPES OF POINT DEFECTS

Page 40: Ic technology- Crystal structure and Crystal growth

Interstitials – atoms that are squeezed in between regular lattice sites.

Self interstitials: If the interstitial atom is of the same species as the lattice atoms, it is called self-interstitial. Creation of a self-interstitial causes a substantial distortions in the surrounding lattice and costs more energy as compared to the energy for creation of a vacancy (Ei > EV).

They introduce less distortion to the lattice and are more common in real materials and more mobile. If the foreign atom atom replaces or substitutes for a matrix atom, it is called a substitutional impurity.

Page 41: Ic technology- Crystal structure and Crystal growth

A Frenkel defect is a pair of cation (positive ion) vacancy and a cation interstitial. Or it may also be an anion (negative ion) vacancy and anion interstitial. However anions are much larger than cations and it is not easy for an anion interstitial to form.

A Schottky defect is a pair of anion and cation vacancies. In both Frenkel and Schottky defects, the pair of point defects stay near each other because of strong coulombic attraction of their opposite charges.

Page 42: Ic technology- Crystal structure and Crystal growth

LINEAR DEFECTS- DISLOCATIONS Dislocations are another type of

defect in crystals. Dislocations are areas were the atoms are out of position in the crystal structure.

Dislocations are generated and move when a stress is applied. The motion of dislocations allows slip – plastic deformation to occur.

Page 43: Ic technology- Crystal structure and Crystal growth

DISLOCATIONS IN UNIT CELLS

Page 44: Ic technology- Crystal structure and Crystal growth

DISLOCATION MOVEMENT

Dislocation moves along slip plane.

Climb of an edge dislocation

Page 45: Ic technology- Crystal structure and Crystal growth

There are two basic types of dislocations, the edge dislocation and the screw dislocation. Actually, edge and screw dislocations are just extreme forms of the possible dislocation structures that can occur. Most dislocations are probably a hybrid of the edge and screw forms but this discussion will be limited to these two types.

Page 46: Ic technology- Crystal structure and Crystal growth

Edge DislocationsThe edge defect can be easily visualized as an extra half-plane of atoms in a lattice.

The dislocation is called a line defect because the locus of defective points produced in the lattice by the dislocation lie along a line.

This line runs along the top of the extra half-plane. The inter-atomic bonds are significantly distorted only in the immediate vicinity of the dislocation line.

Page 47: Ic technology- Crystal structure and Crystal growth

As shown in the set of images above, the dislocation moves similarly moves a small amount at a time.

The dislocation in the top half of the crystal is slipping one plane at a time as it moves to the right from its position in image (a) to its position in image (b) and finally image (c).

Page 48: Ic technology- Crystal structure and Crystal growth

CONTD.. In the process of slipping one plane at a time the

dislocation propagates across the crystal. However, only a small fraction of the bonds are

broken at any given time. Movement in this manner requires a much smaller force than breaking all the bonds across the middle plane simultaneously.

Page 49: Ic technology- Crystal structure and Crystal growth

Screw DislocationsThere is a second basic type of dislocation, called screw dislocation. The screw dislocation is slightly more difficult to visualize.

The motion of a screw dislocation is also a result of shear stress, but the defect line movement is perpendicular to direction of the stress and the atom displacement, rather than parallel.

To visualize a screw dislocation, imagine a block of metal with a shear stress applied across one end so that the metal begins to rip.

Page 50: Ic technology- Crystal structure and Crystal growth

PLANAR DEFECT

Stacking Faults and Twin BoundariesA disruption of the long-range stacking sequence can produce two other common types of crystal defects:

1) a stacking fault 2) a twin region.

Page 51: Ic technology- Crystal structure and Crystal growth

Stacking fault : A stacking fault is a one or two layer interruption in the stacking sequence of atom planes.

Stacking faults occur in a number of crystal structures, but it is easiest to see how they occur in close packed structures.

Page 52: Ic technology- Crystal structure and Crystal growth

Twin boundaries fault: If a stacking fault does not corrects itself immediately but continues over some number of atomic spacings.

It will produce a second stacking fault that is the twin of the first one.

Twin Boundaries fault

Page 53: Ic technology- Crystal structure and Crystal growth

Grain Boundaries in Polycrystals:Another type of planer defect is the grain boundary However, solids generally consist of a number of crystallites or grains.

Grains can range in size from nanometers to millimeters across and their orientations are usually rotated with respect to neighboring grains.

Page 54: Ic technology- Crystal structure and Crystal growth

CONTD.. Where one grain stops and another begins is know as

a grain boundary. .Grain boundaries limit the lengths and motions of

dislocations. Therefore, having smaller grains (more grain boundary

surface area) strengthens a material. The size of the grains can be controlled by the cooling

rate when the material cast or heat treated.

Page 55: Ic technology- Crystal structure and Crystal growth

METALLURGICAL GRADE SILICON The raw material for silicon manufacture is sand,

mostly from the beaches

The sand is heated in a furnace containing a source of carbon,

2C + SiO2 (MGS) Si + 2CO,

where MGS = metallurgical grade silicon.

Although MGS is of relatively high purity (98%), it still contains a number of contaminants (such iron and aluminum).

55VLSI/ULSI Process Technology

Page 56: Ic technology- Crystal structure and Crystal growth

Raw Material and Purification(EGS)-First, the MGS is reacted with HCl to form SiHCl3, (trichlorosilane) which is in liquid form at room temperature,

Si (s) + 3HCl (g) SiHCl3 (g) + H2 (g) + heat

-Fractional distillation results in impurity segregation, and extremely pure SiHCl3 is obtained.

-To convert the SiHCl3 back into purified Si a CVD (Chemical Vapor Deposition) process is used (in a hydrogen atmosphere),

2SiHCl3 (gas)+2H2 (gas) 2Si (solid)+ 6HCl (gas),

-The nucleation surface is thin poly-Si rod, with a final thickness of many inches in diameter,-All that is specified is impurity level, so fast deposition is possible .

56

Page 57: Ic technology- Crystal structure and Crystal growth

MONOCRYSTAL SILICON GROWTH

CZ Method CZ Crystal Puller Doping Impurity Control

Float-Zone Method Reasons for Larger Ingot Diameters

Page 58: Ic technology- Crystal structure and Crystal growth

Wafer growth – Czochralski Method (Cz)

-From the high purity poly-Si, single crystal silicon is required,-The Cz process is the most common for large wafer diameter production.- Pull rate, melt temperature and rotation rate are all important control parameters.

Page 59: Ic technology- Crystal structure and Crystal growth

VLSI/ULSI Process Technology

Page 60: Ic technology- Crystal structure and Crystal growth

Crystal seed

Molten polysilicon

Heat shield

Water jacket

Single crystal silicon

Quartz crucible

Carbon heating

element

Crystal puller and

rotation mechanism

CZ CRYSTAL PULLER

Quartz crucible:Chemically unreactive

High melting pointThermally stable

Hardreusable

60

Page 61: Ic technology- Crystal structure and Crystal growth

CZ CRYSTAL PULLER

61

Page 62: Ic technology- Crystal structure and Crystal growth

IMPURITY SEGREGATION Impurities: intentional and unintentional Equilibrium Segregation coefficient ko = Cs/Cl• Effective segregation constant,

where V= growth velocity or pull rate D= diffusion coefficient of dopant in melt B= Boundary or stagnant layer thickness

Cs=equilibrium concentration of impurity in solid Cl=equilibrium concentration of impurity in liquid

Impurity Al As B C Cu Fe O P Sbko 0.002 0.3 0.8 0.07 4x10-6 8x10-6 0.25 0.35

0.023Segregation constants for common impurities

0

0 0(1 )exp( / )ek

kk k VB D

Page 63: Ic technology- Crystal structure and Crystal growth

IMPURITY DISTRIBUTION The distribution of an impurity in the grown crystal can be

described mathematically by the normal freezing relation

X is the fraction of the melt solidified

Co is the initial melt concentrationCs is the solid concentrationko is the segregation coefficient

The boundary layer thickness is a function of convection conditions in the melt which is given as

1/3 1/ 6 1/ 21.8B D V W Rotational velocity

Page 64: Ic technology- Crystal structure and Crystal growth

PROOF: IMPURITY DISTRIBUTION Initial condition:

- melt volume: Vm - dopant conc. in the melt: Cm

At a given point of growth:- volume of grown crystal: V- amount of dopant remaining in the melt(by weight): S.- conc. of dopant in solid:Cs

- conc. of dopant in liquid: Cl For a volume dV, during freezing

-dS= CsdV

Page 65: Ic technology- Crystal structure and Crystal growth

The remaining weight of the melt is Vm-V, and the doping concentration in the liquid Cl, is given by

Combining two equations and substituting

Given the initial weight of the dopant, , we can integrate and obtain

Solving the equation gives

lm

SCV V

om

dS dVkS V V

0m m

S V

omC V

dS dVkS V V

1

1mk

s o mm

VC k CV

Page 66: Ic technology- Crystal structure and Crystal growth

PULL RATE AND GROWTH RATE Pull rate varies inversely with diameter. Growth rate depends upon the no. of sites on the face of

crystal and heat transfer at the interface and can be greater than pull rate and even be negative.

Seed

Solid Si

Liquid Si

dxC

B

A

Isotherm X2

Isotherm X1

A=Heat of crystallization

B=conduction in solid

C=Radiation

Liquid to solid → HEAT

Freezing interface

Page 67: Ic technology- Crystal structure and Crystal growth

Let

Then Heat balance (A B C): latent heat of crystallization + heat conducted from melt to crystal = heat conducted away.

L latent heat of fusion

dmdt

amount of freezing per unit time

kL thermal conductivity of liquiddTdx1

thermal gradient at isotherm x1

kS thermal conductivity of soliddTdx2

thermal gradient at x2

Ldmdt

kLdTdx1

A1 kSdTdx2

A2

Page 68: Ic technology- Crystal structure and Crystal growth

• If vP is pull rate and d is density, rate of growth of crystal isP

dm v Addt

(2)

• Assuming thermal gradient in the melt be zero, eq. (1) gives:2

SPMAX

k dTvLd dx

(3)

• In order to replace dT/dx2, we need to consider the heat transfer processes.

Seed

Solid Si

Liquid Si

dxC

B

A

Isotherm X2

Isotherm X1

• Heat radiation from the crystal (C) is given by the Stefan-Boltzmann law

dQ 2rdx T4 (4)

• Heat conduction up the crystal is given by

QkS r2 dTdx

(5)

Page 69: Ic technology- Crystal structure and Crystal growth

• Differentiating (5), we have 2 2

2 2 22 2

SS S

dkdQ d T dT d Tk r r k rdx dx dx dx dx

(6)

• Substituting (4) into (6), we have

d2Tdx2 2

kSrT4 0 (7)

• kS varies roughly as 1/T, so if kM is the thermal conductivity at the melting point,

kS kMTMT

(8)

d2Tdx2 2

kMrTMT5 0 (9)

• Solving this differential equation, evaluating it at x = 0 and substituting the result into (3), we obtain :

5213M M

PMAXk Tv

Ld r

(10)

• This gives a max pull rate of ≈ 24 cm hr-1 for a 6” crystal. Actual values are ≈ 2X less than this.

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ADVANTAGES:Growth from free surface (accommodates volume

change).Crystal can be observed.Forced convection easy to impose.High throughput; large crystals can be obtained.High crystalline perfection can be achieved.Good radial homogeneity.

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DRAWBACKS: Materials with high vapor pressure

can not be grown.

Batch process; hard to adapt for continuous growth; result: axial segregation.

The crystal has to be rotated; rotation of the crucible is desirable.

Process requires continuous attention (seeding, necking) and sophisticated control.

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DRAWBACKS (CONTINUED): Melt is thermally upside down. Temperature gradients are high to control the crystal

diameter. High thermal stresses. Shape and size of the crystal is hard to control if

temperature gradients are low.

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ADVANTAGES/DISADVANTAGES TO CZ METHOD Crystals grown by the CZ method are preferred for

VLSI applications since they can withstand thermal stresses better than Float Zone material.

The CZ method is also more cost effective, as it is capable of producing larger crystals (almost 2 meters long and with diameters of greater than 300 mm). 

A critical shortcoming of the CZ method is that oxygen from the silica crucible is transferred into the crystal. CZ wafers must undergo a special process to minimize the effect of oxygen on finished circuits.

Page 74: Ic technology- Crystal structure and Crystal growth

FLOAT ZONE CRYSTAL GROWTH The Float Zone (FZ) growth

method is far less common, and is reserved for situations where oxygen and carbon impurities cannot be tolerated,

The entire poly-Si rod is extracted from the EGS process as a whole.

RF

Gas inlet (inert)

Molten zone

Traveling RF coil

Polycrystalline rod (silicon)

Seed crystal

Inert gas out

Chuck

Chuck

Page 75: Ic technology- Crystal structure and Crystal growth

Another simpler representation of FZ method for wafer preparation

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DOPING IN FZ METHOD Core Doping: refers to doping achieved with doped

polycrystalline Si rod. On top of which undoped polysilicon rod is placed until the average desired concentration is reached. The process can be repeated for several generations.

It is preferred process for Boron as it does not evaporate from the surface of the rod.

Gas doping: Dopants are introduced in gaseous form during FZ growth. n-doping: PH3 (Phosphine), AsCl3 p-doping: B2H6 (Diborane), BCl3 Good uniformity along the length of the boule.

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DOPING IN FZ METHOD CONTD… Pill doping: Drill a small hole in the top of the EGS rod, and insert the

dopant. If the segregation coefficient of dopant is small, most of it

will be carried with the melt as it passes the length of ingot. Ga and In doping work well this way.

Page 78: Ic technology- Crystal structure and Crystal growth

EXAMPLE-1•A BOULE OF SINGLE CRYSTAL SILICON IS PULLED FROM THE MELT IN A CZ PROCESS. THE SI IS BORON DOPED. AFTER THE BOULE IS PULLED , IT IS SLICED INTO THE WAFERS. THE WAFER TAKEN FROM THE TOP OF THE BOULE HAS A BORON CONCENTRATION OF 3 X 1015 CM-3. WHAT WOULD YOU EXPECT FOR DOPING CONCENTRATION OF THE WAFER TAKEN FROM THE POSITION CORRESPONDING TO 90% OF THE INITIAL CHARGE SOLIDIFIED?

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WAFER PREPARATION

Silicon shaping

Etching

and polishin

g

Chemical cleaning

3 basic steps of wafer preparation:

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1. SILICON SHAPING After the single crystal is obtained, this needs to be

further processed to produce the wafers. For this, the wafers need to be shaped and cut.

The shaping operations consist of two steps 1. The seed and tang ends of the ingot are removed.2. . The surface of the ingot is ground to get an uniform

diameter across the length of the ignots.o The ingots are checked for resistivity and orientation.

Resistivity is checked by a four point probe technique and can be used to confirm the dopant concentration. ingot.

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After the orientation and resistivity checks, one or more flats are ground along the length of the ingot.

There are two types of flats.1. Primary flat - this is ground

relative to a specific crystal direction. This acts as a visual reference to the orientation of the wafer.

2. Secondary flat - this used for identification of the wafer, dopant type and orientation.

Page 82: Ic technology- Crystal structure and Crystal growth

2. ETCHING AND POLISHING After grinding the flats, the wafer is dipped in a

chemical etchant to remove damage caused by mechanical grinding.

Etching: Etching is used in microfabrication to chemically remove layers from the surface of a wafer during manufacturing.

This is usually done in an acid bath with a mixture of hydrofluoric acid, nitric acid, and acetic acid.

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Polishing: This process allows to attain the super-flat, mirrored surface with a remaining roughness on atomic scale.

First a rough abrasive polish, followed by a chemical mechanical polishing (CMP) procedure. In CMP, a slurry of fine SiO2 particles suspended in aqueous NaOH solution is used. The pad is usually a polyester material.

Polishing happens both due to mechanical abrasion and also reaction of the silicon with the NaOH solution.

Page 84: Ic technology- Crystal structure and Crystal growth

CHEMICAL CLEANING Metal equipment must be cleaned from time to time

to prevent damage and maintain efficiency of operation.

Step 1 - Cleaning with alkali. Step 2 – Rinsing. Step 3 - Cleaning with acid. Step 4 – Rinsing. Step 5 - Passifying with alkali.