Correlations
between physical properties linking film quality with wet etch rate
(WER), one of the leading figures of merit, in plasma-enhanced atomic
layer deposition (PEALD) grown silicon nitride (SiN
x
) films remain largely unresearched. Achieving a low WER of
a SiN
x
film is especially significant
in its use as an etch stopper for technology beyond 7 nm node semiconductor
processing. Herein, we explore the correlation between the hydrogen
concentration, hydrogen bonding states, bulk film density, residual
impurity concentration, and the WERs of PEALD SiN
x
using Fourier transform infrared spectrometry, X-ray reflectivity,
and spectroscopic ellipsometry, etc. PEALD SiN
x
films for this study were deposited using hexachlorodisilane
and hollow cathode plasma source under a range of process temperatures
(270–360 °C) and plasma gas compositions (N2/NH3 or Ar/NH3) to understand the influence
of hydrogen concentration, hydrogen bonding states, bulk film density,
and residual impurity concentration on the WER. Varying hydrogen concentration
and differences in the hydrogen bonding states resulted in different
bulk film densities and, accordingly, a variation in WER. We observe
a linear relationship between hydrogen bonding concentration and WER
as well as a reciprocal relationship between bulk film density and
WER. Analogous to the PECVD SiN
x
processes,
a reduction in hydrogen bonding concentration arises from either (1)
thermal activation or (2) plasma excited species. However, unlike
the case with silane (SiH4)-based PECVD SiN
x
, PEALD SiN
x
WERs are
affected by residual impurities of Si precursors (i.e., chlorine impurity).
Thus, possible wet etching mechanisms in HF in which the WER is affected
by hydrogen bonding states or residual impurities are proposed. The
shifts of amine basicity in SiN
x
due to
different hydrogen bonding states and the changes in Si electrophilicity
due to Cl impurity content are suggested as the main mechanisms that
influence WER in the PEALD processes.