Effects of differential etching and masking resist preparation on the quality of the reactive-ion-etched aluminum and aluminum alloys

Abstract

The conventional method used for aluminum (Al) and aluminum alloy (Al + Si, Al + Si + Cu) delineation in integrated circuits is mainly by wet chemical etching. Because of its isotropic characteristic, wet chemical etching becomes inadequate for patterning Al metal lines with linewidths narrower than about 4 Μm. In this work, Al and Al alloys (Al + 2% Si; Al + 1% Si + 1% Cu) were reactively etched in SiCl4 plasma using patterned photoresist as the etch-mask. Resist patterns were generated either by conventional processing methods or by tri-level resist techniques which included hard-baking (200°C, ≤ 30 min), and two consecutive reactive ion etchings in CF4 and 02 plasmas. Masking resists prepared by the tri-level resist technique retained their integrity during exposure to a SiCl4 plasma, and significantly improved resolution and fidelity of pattern transfer from resist to underlying Al or Al alloy film. The substrate surface of the reactively etched Al + Si + Cu sample was considerably rougher than that of the Al or Al + Si sample due to the high concentration of Cu accumulated at the metal/substrate region during RIE process.