To: Ian@SI who wrote (3614 ) 10/21/2000 10:20:45 AM From: Proud_Infidel Respond to of 3736 CMP may end up getting replaced by 'electropolishing' in copper processes A key problem in finding a low-k dielectric insulator for copper interconnects has been to find one that can hold up under the stress and strain of chemical mechanical polishing (CMP). Many insulating materials with lower dielectric-constant ratings can't meet the mechanical-strength requirements for CMP, which is used to flatten layers in interconnects and remove excess amounts of copper from vias and trenches. But help may be on the way. ACM Research, a Silicon Valley startup, has developed new current-controlled electroplating and electropolishing technologies that it claims "will dramatically ease" processing steps for next-generation copper and low-k dielectrics on ICs. "Our electropolishing system is 'stress free polishing,'" claims ACM's CEO, David Wang. These processes and the new tools to go with them use electrical current to control locally the deposition of copper, plating steps, removal of metal, and polishing sequences. The novel electropolishing process and tool is said to be capable of removing materials at the atomic layer down to 80 angstroms. Switching from CMP to these electropolishing techniques for planarization in dual damascene copper processes opens up a wide range of choices for low-k dielectric materials that couldn't cut it before because they couldn't withstand the stress of CMP. Now, softer dielectric films such as spin-on, porous Xerogel materials have become viable candidates for integration in damascene processes with copper. These porous films can be "tunable" and have low-k dielectric ratings less than 1.8 vs. above 3 for many of the current low-k insulators being used in prototype copper processes. Other companies also are pursuing alternatives to CMP. If the new technology catches on, it could threaten a huge wafer tool segment that is expected to top $1.2 billion in sales by 2003, according to VLSI Research. "There may not be a need for copper CMP," Wang adds. He believes his company's patented concepts also will extend the use of copper electroplating to the 0.035-micron technology node, which is still expected to be in use more than a decade from now. The cost of his alternative to CMP will run less than $2 per wafer vs. $4-to-5 with CMP tools, Wang claims.