FinFET History, Fundamentals and Future Tsu‐Jae King Liu Department of Electrical Engineering and Computer Sciences University of California, Berkeley, CA 94720‐1770 USA June 11, 2012 2012 Symposium on VLSI Technology Short Course Impact of Moore’s Law Transistor Scaling Higher Performance, Investment Lower Cost # DEVICES (MM) Market Growth CMOS generation: 1 um • • 180 nm • • 32 nm Source: ITU, Mark Lipacis, Morgan Stanley Research YEAR http://www.morganstanley.com/institutional/techresearch/pdfs/2SETUP_12142009_RI.pdf 2 1996: The Call from DARPA • 0.25 m CMOS technology was state‐of‐the‐art • DARPA Advanced Microelectronics (AME) Program Broad Agency Announcement for 25 nm CMOS technology 1998 International Technology Roadmap for Semiconductors (ITRS) Technology Node Gate Oxide Thickness, TOX (nm) Drive Current, IDSAT 1999 2002 2005 2008 2011 2014 2017 2020 180 nm 130 nm 100 nm 70 nm 50 nm 35 nm 25 nm 18 nm 1.9‐2.5 1.5‐1.9 1.0‐1.5 0.8‐1.2 0.6‐0.8 0.5‐0.6 Solutions being pursued No known solutions End of Roadmap UC‐Berkeley project “Novel Fabrication, Device Structures, and Physics of 25 nm FETs for Terabit‐Scale Electronics” • June 1997 through July 2001 3 MOSFET Fundamentals Metal Oxide Semiconductor Field‐Effect Transistor: 0.25 micron MOSFET XTEM GATE LENGTH, Lg Gate Source Drain Si substrate http://www.eetimes.com/design/automotive‐design/4003940/LCD‐driver‐highly‐integrated GATE OXIDE THICKNESS, Tox 4 MOSFET Operation: Gate Control N‐channel MOSFET Desired cross‐section characteristics: • High ON current Gate • Low OFF current gate oxide Leff N+ P Source Body • Current between Source and Drain is controlled by the Gate voltage. • “N‐channel” & “P‐channel” MOSFETs operate in a complementary manner N+ “CMOS” = Complementary MOS Drain log ID increasing E n(E) exp (‐E/kT) Sourceincreasing VGS distance ION DRAIN CURRENT Electron Energy Band Profile Inverse slope is subthreshold swing, S [mV/dec] IOFF Drain 0 VTH GATE VOLTAGE VDD 5 CMOS Devices and Circuits CIRCUIT SYMBOLS N‐channel P‐channel MOSFET MOSFET D S D INVERTER LOGIC SYMBOL VDD G G S CMOS INVERTER CIRCUIT VOUT VDD S D V D OUT VIN GND S 0 CMOS NAND GATE VDD VIN STATIC MEMORY (SRAM) CELL NOT AND (NAND) TRUTH TABLE WORD LINE BIT LINE 0 or 1 1 or 0 BIT LINE 6 Improving the ON/OFF Current Ratio Gate log ID Cox Cdep Source Body S ION Ctotal Cox Drain VDD VGS • The greater the capacitive coupling between Gate and channel, the better control the Gate has over the channel potential. higher ION/IOFF for fixed VDD, or lower VDD to achieve target ION/IOFF reduced drain‐induced barrier lowering (DIBL): log ID Source increasing VDS Drain increasing VDS IOFF VGS 7 MOSFET in ON State (VGS > VTH) width velocity inversion‐layer charge density I D W v Qinv v eff gate‐oxide capacitance Qinv Cox (VGS VTH ) gate overdrive mobility DRAIN CURRENT, ID Gate Source Drain Substrate DRAIN VOLTAGE, VDS 8 Effective Drive Current (IEFF) CMOS inverter chain: VDD V2 S D VIN D GND S VOUT V3 NMOS DRAIN CURRENT V1 VDD VDD/2 V2 V1 tpLH tpHL IH + IL IEFF = 2 V3 TIME IDSAT IH (DIBL = 0) VIN = VDD IH VIN = 0.83VDD VIN = 0.75VDD IL 0.5VDD VIN = 0.5VDD VDD NMOS DRAIN VOLTAGE = VOUT M. H. Na et al. (IBM), IEDM Technical Digest, pp. 121‐124, 2002 9 CMOS Technology Scaling XTEM images with the same scale courtesy V. Moroz (Synopsys, Inc.) 90 nm node T. Ghani et al., IEDM 2003 65 nm node (after S. Tyagi et al., IEDM 2005) 45 nm node 32 nm node K. Mistry et al., IEDM 2007 P. Packan et al., IEDM 2009 • Gate length has not scaled proportionately with device pitch (0.7x per generation) in recent generations. – Transistor performance has been boosted by other means. 10 MOSFET Performance Boosters • Strained channel regions eff • High‐k gate dielectric and metal gate electrodes Cox Cross‐sectional TEM views of Intel’s 32 nm CMOS devices P. Packan et al. (Intel), IEDM Technical Digest, pp. 659‐662, 2009 11 Process‐Induced Variations • Sub‐wavelength lithography: – Resolution enhancement techniques are costly and increase process sensitivity • Gate line‐edge roughness: courtesy Mike Rieger (Synopsys, Inc.) photoresist • Random dopant fluctuations (RDF): – Atomistic effects become significant in nanoscale FETs SiO2 Source Gate Drain A. Brown et al., IEEE Trans. Nanotechnology, p. 195, 2002 A. Asenov, Symp. VLSI Tech. Dig., p. 86, 2007 12 A Journey Back through Time… Why New Transistor Structures? • Off‐state leakage (IOFF) must be suppressed as Lg is scaled down – allows for reductions in VTH and hence VDD • Leakage occurs in the region away from the channel surface Let’s get rid of it! Lg Ultra‐Thin‐Body MOSFET: Gate Gate Source Source Drain Drain Buried Oxide Substrate “Silicon‐on‐ Insulator” (SOI) Wafer 14 Thin‐Body MOSFETs • IOFF is suppressed by using an adequately thin body region. – Body doping can be eliminated higher drive current due to higher carrier mobility Reduced impact of random dopant fluctuations (RDF) Ultra‐Thin Body (UTB) Double‐Gate (DG) Lg Gate Gate Source Drain Buried Oxide TSi Drain Source TSi Gate Substrate TSi < (1/4) Lg B. Yu et al., ISDRS 1997 TSi < (2/3) Lg R.‐H. Yan et al., IEEE TED 1992 15 Effect of TSi on Leakage Lg = 25 nm; Tox,eq = 12Å TSi = 10 nm TSi = 20 nm G G 106 Si Thickness [nm] 0.0 S D 3x102 G 8.0 12.0 S D 16.0 20.0 10‐1 Leakage Current Density [A/cm2] @ VDS = 0.7 V 4.0 G Ioff = 2.1 nA/m Ioff = 19 A/m 16 Double‐Gate MOSFET Structures PLANAR: VERTICAL FIN: L. Geppert, IEEE Spectrum, October 2002 17 DELTA MOSFET D. Hisamoto, T. Kaga, Y. Kawamoto, and E. Takeda (Hitachi Central Research Laboratory), “A fully depleted lean‐channel transistor (DELTA) – a novel vertical ultrathin SOI MOSFET,” IEEE Electron Device Letters Vol. 11, pp. 36‐39, 1990 • Improved gate control observed for Wg < 0.3 m – Leff= 0.57 m Wl = 0.4 m 18 Double‐Gate FinFET • Self‐aligned gates straddle narrow silicon fin • Current flows parallel to wafer surface Gate Length, Lg Source S G D Gate 1 Drain Current Flow Gate 2 G Fin Height, Hfin Fin Width, Wfin 19 1998: First N‐channel FinFETs D. Hisamoto, W.‐C. Lee, J. Kedzierski, E. Anderson, H. Takeuchi, K. Asano, T.‐J. King, J. Bokor, and C. Hu, “A folded‐channel MOSFET for deep‐sub‐tenth micron era,” IEEE International Electron Devices Meeting Technical Digest, pp. 1032‐1034, 1998 Plan View Lg = 30 nm Wfin = 20 nm Hfin = 50 nm Lg = 30 nm Wfin = 20 nm Hfin = 50 nm • Devices with Lg down to 17 nm were successfully fabricated 20 1999: First P‐channel FinFETs X. Huang, W.‐C. Lee, C. Kuo, D. Hisamoto, L. Chang, J. Kedzierski, E. Anderson, H. Takeuchi, Y.‐K. Choi, K. Asano, V. Subramanian, T.‐J. King, J. Bokor, and C. Hu, “Sub 50‐nm FinFET: PMOS,” IEEE International Electron Devices Meeting Technical Digest, pp. 67‐70, 1999 Lg = 18 nm Wfin = 15 nm Hfin = 50 nm Transmission Electron Micrograph 21 2000: Vested Interest from Industry • Semiconductor Research Corporation (SRC) & AMD fund project: – Development of a FinFET process flow compatible with a conventional planar CMOS process – Demonstration of the compatibility of the FinFET structure with a production environment (October 2000 through September 2003) • DARPA/SRC Focus Center Research Program funds projects: – Approaches for enhancing FinFET performance (MSD Center, April 2001 through August 2003) – FinFET‐based circuit design (C2S2 Center, August 2003 through July 2006) 22 FinFET Structures Original: Gate‐last process flow Gate Source Si Fin Drain Gate Improved: Gate‐first process flow Source Drain 23 Fin Width Requirement Measured FinFET DIBL • To adequately suppress DIBL, Lg/Wfin > 1.5 Challenge for lithography! N. Lindert et al. (UC‐Berkeley), IEEE Electron Device Letters, Vol. 22, pp. 487‐489, 2001 24 Sub‐Lithographic Fin Patterning Spacer Lithography a.k.a. Sidewall Image Transfer (SIT) and Self‐Aligned Double Patterning (SADP) 1. Deposit & pattern sacrificial layer 3. Etch back mask layer to form “spacers” SOI SOI BOX BOX 2. Deposit mask layer (SiO2 or Si3N4) 4. Remove sacrificial layer; etch SOI layer to form fins SOI fins BOX BOX Note that fin pitch is 1/2 that of patterned layer 25 Benefits of Spacer Lithography • Spacer litho. provides for better CD control and uniform fin width SEM image of FinFET with spacer‐defined fins: Y.‐K. Choi et al. (UC‐Berkeley), IEEE Trans. Electron Devices, Vol. 49, pp. 436‐441, 2002 26 Spacer‐Defined FinFETs Y.‐K. Choi, N. Lindert, P. Xuan, S. Tang, D. Ha, E. Anderson, T.‐J. King, J. Bokor, and C. Hu, "Sub‐20nm CMOS FinFET technologies,” IEEE International Electron Devices Meeting Technical Digest, pp. 421‐424, 2001 Lg = 60 nm, Wfin = 40 nm Transfer Characteristics Output Characteristics 27 2001: 15 nm FinFETs -2 10 -4 10 -6 10 -8 10 Transfer Characteristics -2 Vd=-1.0 V P+Si0.4Ge0.6 Vd=1.0 V Gate Vd=0.05 V Vd=-0.05 V N-body= 18 -3 2x10 cm 10 -6 10 10 -10 10 -4 -8 -10 10 -12 10 10 NMOS PMOS -1.0 -0.5 0.0 0.5 1.0 1.5 Gate Voltage, Vg [V] -12 10 2.0 Drain Current, Id[uA/um] Drain Current, Id [A/um] Y.‐K. Choi, N. Lindert, P. Xuan, S. Tang, D. Ha, E. Anderson, T.‐J. King, J. Bokor, C. Hu, "Sub‐20nm CMOS FinFET technologies,” IEEE International Electron Devices Meeting Technical Digest, pp. 421‐424, 2001 Output Characteristics 600 500 600 PMOS 400 |Vg-Vt|=1.2V NMOS 400 Voltage step : 0.2V 300 500 300 200 200 100 100 0 -1.5 -1.0 -0.5 0.0 0.5 1.0 0 1.5 Drain Voltage, Vd [V] Wfin = 10 nm; Tox = 2.1 nm 28 2002: 10 nm FinFETs SEM image: B. Yu, L. Chang, S. Ahmed, H. Wang, S. Bell, C.‐Y. Yang, C. Tabery, C. Hu, T.‐J. King, J. Bokor, M.‐R. Lin, and D. Kyser, "FinFET scaling to 10nm gate length," International Electron Devices Meeting Technical Digest, pp. 251‐254, 2002 Output Characteristics TEM images • These devices were fabricated at AMD, using optical lithography. 29 Hole Mobility Comparison Measured Field‐Effect Hole Mobility Mobility(cm2/V-sec) 160 140 Vg-Vth=.8V 120 <100> channel • DG FET has higher hole mobility due to lower transverse electric field 100 80 FinFET • For the same gate overdrive, hole mobility in DG‐FinFET is 2× that in a control bulk FET 60 Bulk FET 40 20 0 0 0.5 Effective Field (MV/cm) 1 30 FinFET Process Refinements Y.‐K. Choi, L. Chang, P. Ranade, J. Lee, D. Ha, S. Balasubramanian, A. Agarwal, T.‐J. King, and J. Bokor, "FinFET process refinements for improved mobility and gate work function engineering," IEEE International Electron Devices Meeting Technical Digest, pp. 259‐262, 2002 Fin‐sidewall smoothening for improved carrier mobilities Gate work function tuning for VTH adjustment 31 FinFET Reliability Id / Id [%] Y.‐K. Choi, D. Ha, J. Bokor, and T.‐J. King, “Reliability study of CMOS FinFETs,” IEEE International Electron Devices Meeting Technical Digest, pp. 177‐180, 2003 30 Stress Bias Condition: Vg=Vd=2.0V 20 • Narrower fin improved hot‐carrier (HC) immunity Lg=80nm 10 • HC lifetime and oxide QBD are also improved by smoothening the Si fin sidewall surfaces (by H2 annealing) VT / VT [%] 0 -10 -20 -30 0 10 W fin=18nm W fin=34nm 1 W fin=26nm W fin=42nm 2 10 10 Stress Time [sec] 3 10 32 Tri‐Gate FET Lg = 60 nm Wfin = 55 nm Hfin = 36 nm B. Doyle et al. (Intel), IEEE Electron Device Letters, Vol. 24, pp. 263‐265, 2003 33 SOI Multi‐Gate MOSFET Designs Tri‐Gate FET Relaxed fin dimensions WSi > Lg/2; HSi > Lg/5 HSi / Leff FinFET Narrow fin WSi ~ Lg/2 body dimensions required for DIBL=100 mV/V Tox = 1.1nm WSi / Leff UTB FET Ultra‐thin SOI HSi ~ Lg/5 after Yang and Fossum, IEEE Trans. Electron Devices, Vol. 52, pp. 1159‐1164, 2005 34 Double‐Gate vs. Tri‐Gate FET • The Double‐Gate FET does not require a highly selective gate etch, due to the protective dielectric hard mask. • Additional gate fringing capacitance is less of an issue for the Tri‐Gate FET, since the top fin surface contributes to current conduction in the ON state. Double‐Gate FET Tri‐Gate FET channel after M. Khare, 2010 IEDM Short Course 35 Independent Gate Operation • The gate electrodes of a double‐gate FET can be isolated by a masked etch, to allow for separate biasing. – One gate is used for switching. – The other gate is used for VTH control. Drain Gate1 Gate2 Back‐ Gated FET Source D. M. Fried et al. (Cornell U.), IEEE Electron Device Letters, Vol. 25, pp. 199‐201, 2004 L. Mathew et al. (Freescale Semiconductor), 2004 IEEE International SOI Conference 36 Bulk FinFET • FinFETs can be made on bulk‐Si wafers lower cost improved thermal conduction with super‐steep retrograde well (SSRW) or “punch‐ through stopper” at the base of the fins • 90 nm Lg FinFETs demonstrated Wfin = 80 nm Hfin = 100 nm DIBL = 25 mV C.‐H. Lee et al. (Samsung), Symposium on VLSI Technology Digest, pp. 130‐131, 2004 37 Bulk vs. SOI FinFET (compared to SOI FinFET) H. Bu (IBM), 2011 IEEE International SOI Conference 38 2004: High‐k/Metal Gate FinFET D. Ha, H. Takeuchi, Y.‐K. Choi, T.‐J. King, W. Bai, D.‐L. Kwong, A. Agarwal, and M. Ameen, “Molybdenum‐gate HfO2 CMOS FinFET technology,” IEEE International Electron Devices Meeting Technical Digest, pp. 643‐646, 2004 39 IDSAT Boost with Embedded‐SiGe S/D Process flow: IOFF vs. ION Lg = 50 nm Wfin = 35 nm Hfin = 65 nm • 25% improvement in IDSAT is achieved with silicon‐ germanium source/drain, due in part to reduced parasitic resistance P. Verheyen et al. (IMEC), Symposium on VLSI Technology Digest, pp. 194‐195, 2005 40 Fin Design Considerations • Fin Width Gate Length – Limited by etch technology – Tradeoff: layout efficiency vs. design flexibility Drain • Fin Height Source – Determines DIBL • Fin Pitch – Determines layout area Fin Height Pfin Fin Width – Limits S/D implant tilt angle – Tradeoff: performance vs. layout efficiency 41 FinFET Layout • Layout is similar to that of conventional MOSFET, except Pfin that the channel width is quantized: Source Gate Source Gate Drain Drain Source Source Bulk‐Si MOSFET FinFET The S/D fins can be merged by selective epitaxy: M. Guillorn et al. (IBM), Symp. VLSI Technology 2008 Intel Corp. 42 Impact of Fin Layout Orientation • If the fin is oriented || or to the wafer flat, the channel surfaces lie along (110) planes. – lower electron mobility – higher hole mobility (Series resistance is more significant at shorter Lg.) • If the fin is oriented 45° to the wafer flat, the channel surfaces lie along (100) planes. L. Chang et al. (IBM), SISPAD 2004 43 FinFET‐Based SRAM Design Best Paper Award: Z. Guo, S. Balasubramanian, R. Zlatanovici, T.‐J. King, and B. Nikolic, “FinFET‐based SRAM design,” Int’l Symposium on Low Power Electronics and Design, pp. 2‐7, 2005 6‐T SRAM Cell Designs Cell Layouts Butterfly Curves Reduced cell area with independently gated PGs 44 State‐of‐the‐Art FinFETs 22nm/20nm high‐performance CMOS technology • Lg = 25 nm XTEM Images of Fin C.C. Wu et al. (TSMC), IEDM 2010 45 Looking to the Future… 2010 International Technology Roadmap for Semiconductors (ITRS) 2012 Gate Length 2014 2016 2018 2020 2022 2024 24 nm 18 nm 15 nm 13 nm 11 nm 10 nm 7 nm Gate Oxide Thickness, TOX (nm) Drive Current, IDSAT End of Roadmap (always ~15 yrs away!) 46 FinFET vs. UTBB SOI MOSFET Cross‐sectional TEM views of 25 nm UTB SOI devices NFET TSi = 5 nm PFET TSi = 5 nm K. Cheng et al. (IBM), Symposium on VLSI Technology Digest, pp. 128‐129, 2011 B. Doris (IBM), 2011 IEEE International SOI Conference *C.C. Wu et al. (TSMC), IEDM 2010 47 Projections for FinFET vs. UTBB SOI MOSFETs NMOS: Electron Mobility Electron Mobility (cm2/V.s) 300 FDSOI Open: FinFET Closed: FDSOI 250 Unstrained Longi. Trans. Vertical 200 150 Unstrained Longi. Trans. Vertical FinFET 100 12 12 12 Unstrained Longi. Trans. Vertical 12 13 2x10 4x10 6x10 8x10 10 -2 Inversion Charge Concentration (cm ) Hole Mobility Hole Mobility (cm2/V.s) Technology Node: PMOS: Open: FinFET Closed: FDSOI 300 270 240 210 180 20nm tSOI =7nm; tFIN =10nm Unstrained Longi. Trans. Vertical 12 12 12 12 13 2x10 4x10 6x10 8x10 10 -2 Inversion Charge Concentration (cm ) 14/16nm tSOI =5nm; tFIN =7.5nm FinFET Unstrained Longi. Trans. Vertical 12 12 12 13 10/12nm tSOI =3.5nm; tFIN =5nm 0 0 0 0 0 FinFET 12 2x10 4x10 6x10 8x10 10 -2 Inversion Charge Concentration (cm ) 150 0 120 0 90 0 Unstrained Longi. Trans. Vertical FinFET FDSOI FDSOI 60 12 12 0 FDSOI 12 12 13 2x10 4x10 6x10 8x10 10 -2 Inversion Charge Concentration (cm ) 12 12 12 12 13 2x10 4x10 6x10 8x10 10 -2 Inversion Charge Concentration (cm ) 12 12 12 12 13 2x10 4x10 6x10 8x10 10 -2 Inversion Charge Concentration (cm ) N. Xu et al. (UC‐Berkeley), IEEE Electron Device Letters, Vol. 33, pp. 318‐320, 2012 48 Remaining FinFET Challenges • VTH adjustment – Requires gate work‐function (WF) or Leff tuning – Dynamic VTH control is not possible for high‐aspect‐ratio multi‐fin devices • Fringing capacitance between gate and top/bottom of S/D – Mitigated by minimizing fin pitch and using via‐contacted, merged S/D M. Guillorn, Symp. VLSI Technology 2008 • Parasitic resistance – Uniform S/D doping is difficult to achieve with conventional implantation Conformal doping is needed e.g. Y. Sasaki, IEDM 2008 H. Kawasaki, IEDM 2008 • Variability – Performance is very sensitive to fin width – WF variation dominant for undoped channel T. Matsukawa, Symp. VLSI Technology 2008 49 Random Dopant Fluctuation Effects • Channel/body doping can be eliminated to mitigate RDF effects. • However, due to source/drain doping, a trade‐off exists between performance & RDF tolerance for Lg < 10nm: ION vs. TSi IOFF and VT vs. TSi 1E-4 SD = 3nm 75 VT (mV) IOFF (A / m) 1E-6 50 1E-8 Lg = 9nm, EOT = 0.7nm 1E-10 25 4.5 SD = 3nm 100 5.5 TSi (nm) 6.5 0 ION (mA / m) SOI FinFET w/ atomistic S/D gradient regions: 0.8 0.4 4.5 5.5 TSi (nm) V. Varadarajan et al. (UC-Berkeley), IEEE Silicon Nanoelectronics Workshop, 2006 6.5 50 HSi / Leff Bulk vs. SOI Multi‐Gate FET Design • To ease the fin width requirement, the fin height should be reduced. tri‐gate SOI (thick BOX) [J.G. Fossum et al., IEDM 2004] WSi / Leff • The bulk tri‐gate design has the most relaxed body dimension requirements. SSRW (at the base of the fin) improves electrostatic integrity X. Sun et al. (UC‐Berkeley), IEEE Electron Device Letters, Vol. 29, pp. 491‐493, 2008 51 SOI MOSFET Evolution • The Gate‐All‐Around (GAA) structure provides for the greatest capacitive coupling between the gate and the channel. http://www.electroiq.com/content/eiq-2/en/articles/sst/print/volume-51/issue-5/features/nanotechnology/fully-gate-all-around-silicon-nanowire-cmos-devices.html 52 Scaling to the End of the Roadmap 32 nm planar 22 nm multi‐gate segmented channel beyond 10 nm stacked nanowires 3‐D: Intel Corp. quasi‐planar: P. Packan et al. (Intel), IEDM 2009 B. Ho (UCB), ISDRS 2011 C. Dupré et al. (CEA‐LETI) IEDM 2008 Stacked gate‐all‐around (GAA) FETs achieve the highest layout efficiency. 53 Summary • The FinFET was originally developed for manufacture of self‐aligned double‐gate MOSFETs, to address the need for improved gate control to suppress IOFF, DIBL and process‐induced variability for Lg < 25nm. • Tri‐Gate and Bulk variations of the FinFET have been developed to improve manufacturability and cost. • It has taken ~10 years to bring “3‐D” transistors into volume production. • Multi‐gate MOSFETs provide a pathway to achieving lower power and/or improved performance. • Further evolution of the MOSFET to a stacked‐channel structure may occur by the end of the roadmap. 54 Acknowledgments • Collaborators at UC‐Berkeley Profs. Hu, King, Bokor Prof. Subramanian Digh Hisamoto Hideki Takeuchi Xuejue Huang Wen-Chin Lee Jakub Kedzierski Yang‐Kyu Choi Stephen Tang Peiqi Xuan Leland Chang Nick Lindert Sriram Kyoungsub Balasubramanian Zheng Guo Pushkar Ranade, Charles Kuo, Daewon Ha Shin Radu Zlatanovici Prof. Nikolic • Early research funding: DARPA, SRC, AMD • UC Berkeley Microfabrication Laboratory (birthplace of the FinFET) 55