Fabrication and Characterization of AlGaN/GaN Metal-Insulator-Semiconductor High Electron Mobility Transistors for High Power Applications

AlGaN/GaN metal–insulator–semiconductor high electron mobility transistors (MIS-HEMTs) are promising candidates for next generation high-efficiency and high-voltage power applications. The excellent physical properties of GaN-based materials, featuring high critical electric field and large carrier saturation velocity, combined to the high carrier density and large mobility of the two-dimensional electron gas confined at the AlGaN/GaN interface, enable higher power density minimizing power losses and self-heating of the device. However, the advent of the GaN-based MIS-HEMT to the industrial production is still hindered by technological challenges that are being faced in parallel. Among them, one of the biggest challenge is represented by the insertion of a gate dielectric in MIS-HEMTs compared to Schottky-gate HEMTs, which causes operational instability due to the presence of high-density trap states located at the dielectric/III-nitride interface or within the dielectric. The development of a gold-free ohmic contact technology is another important concern since the high-volume and cost-effective production of GaN-based transistors also depends on the cooperative manufacturing of GaN-based devices in Si production facilities, where gold represents an undesidered source of contamination. In fact, even though over the past years there have been multiple attemps to develop gold-free ohmic contacts, there is still no full understanding of the contact formation and current transport mechanism. The first objective of this work was the investigation of a gold-free and low-resistive ohmic contact technology to AlGaN/GaN based on sputtered Ta/Al-based metal stacks annealed at low temperatures. A low contact resistance below 1 Ω mm was obtained using Ta/Al-based metal stacks annealed at temperatures below 600 °C. The ohmic behavior and the contact properties of contact resistance, optimum annealing temperature and thermal stability of Ta/Al-based contacts were studied. The nature of the current transport was also investigated indicating a contact mechanism governed by thermionic field emission tunneling through the AlGaN barrier. Finally, gold-free Ta/Al-based ohmic contacts were integrated in MIS-HEMTs fabricated on a 150 mm GaN-on- Si substrate, demonstrating to be a promising contact technology for AlGaN/GaN devices and revealing to be beneficial for devices operating at high temperatures. The optimization of the MIS-gate structure in terms of trap states at the dielectric/III-nitride interface and inside the dielectric in MIS-HEMTs using atomic layer deposited (ALD) Al2O3 as gate insulator was the second focus of this work. First, the MIS-gate structure was improved by an O2 plasma surface preconditioning applied before the Al2O3 deposition and by an N2 postmetallization anneal applied after gate metallization, which significantly reduced trap states at the Al2O3/GaN interface and within the dielectric. Afterwards, the effectiveness of these treatments was demonstrated in Al2O3-AlGaN/GaN MIS-HEMTs by pulsed current–voltage measurements revealing improved threshold voltage stability. Lastly, it was shown that also the lower annealing temperatures used for the formation of Ta/Al-based ohmic contacts, processed before gate dielectric deposition, are beneficial in terms of trap states at the ALD-Al2O3/GaN interface, representing a new aspect to be considered when using an ohmic first fabrication approach

Design, Fabrication and Characterization of GaN HEMTs for Power Switching Applications

The unique properties of the III-nitride heterostructure, consisting of gallium nitride (GaN), aluminium nitride (AlN) and their ternary compounds (e.g. AlGaN, InAlN), allow for the fabrication of high electron mobility transistors (HEMTs). These devices exhibit high breakdown fields, high electron mobilities and small parasitic capacitances, making them suitable for wireless communication and power electronic applications. In this work, GaN-based power switching HEMTs and low voltage, short-channel HEMTs were designed, fabricated, and characterized.In the first part of the thesis, AlGaN/GaN-on-SiC high voltage metal-insulator-semiconductor (MIS)HEMTs fabricated on a novel ‘buffer-free’ heterostructure are presented. This heterostructure effectively suppresses buffer-related trapping effects while maintaining high electron confinement and low leakage currents, making it a viable material for high voltage, power electronic HEMTs. This part of the thesis covers device processing techniques to minimize leakage currents and maximize breakdown voltages in these ‘buffer-free’ MISHEMTs. Additionally, a recess-etched, Ta-based, ohmic contact process was utilized to form low-resistive ohmic contacts with contact resistances of 0.44-0.47 Ω∙mm. High voltage operation can be achieved by employing a temperature-stable nitrogen implantation isolation process, which results in three-terminal breakdown fields of 98-123 V/μm. By contrast, mesa isolation techniques exhibit breakdown fields below 85 V/μm and higher off-state leakage currents. Stoichiometric low-pressure chemical vapor deposition (LPCVD) SiNx passivation layers suppress gate currents through the AlGaN barrier below 10 nA/mm over 1000 V, which is more than two orders of magnitude lower compared to Si-rich SiNx passivation layers. A 10% dynamic on-resistance increase at 240 V was measured in HEMTs with stoichiometric SiNx passivation, which is likely caused by slow traps with time constants over 100 ms. SiNx gate dielectrics display better electrical isolation at high voltages compared to HfO2 and Ta2O5. However, the two gate oxides exhibit threshold voltages (Vth) above -2 V, making them a promising alternative for the fabrication of recess-etched normally-off MISHEMTs.Reducing the gate length (Lg) to minimize losses and increase the operating frequency in GaN HEMTs also entails more severe short-channel effects (SCEs), limiting gain, output power and the maximum off-state voltage. In the second part of the thesis, SCEs were studied in short-channel GaN HEMTs using a drain-current injection technique (DCIT). The proposed method allows Vth to be obtained for a wide range of drain-source voltages (Vds) in one measurement, which then can be used to calculate the drain-induced barrier lowering (DIBL) as a rate-of-change of Vth with respect to Vds. The method was validated using HEMTs with a Fe-doped GaN buffer layer and a C-doped AlGaN back-barrier with thin channel layers. Supporting technology computer-aided design (TCAD) simulations indicate that the large increase in DIBL is caused by buffer leakage. This method could be utilized to optimize buffer design and gate lengths to minimize on-state losses and buffer leakage currents in power switching HEMTs

Thermo-Piezo-Electro-Mechanical Simulation of AlGaN (Aluminum Gallium Nitride) / GaN (Gallium Nitride) High Electron Mobility Transistor

Due to the current public demand of faster, more powerful, and more reliable electronic devices, research is prolific these days in the area of high electron mobility transistor (HEMT) devices. This is because of their usefulness in RF (radio frequency) and microwave power amplifier applications including microwave vacuum tubes, cellular and personal communications services, and widespread broadband access. Although electrical transistor research has been ongoing since its inception in 1947, the transistor itself continues to evolve and improve much in part because of the many driven researchers and scientists throughout the world who are pushing the limits of what modern electronic devices can do. The purpose of the research outlined in this paper was to better understand the mechanical stresses and strains that are present in a hybrid AlGaN (Aluminum Gallium Nitride) / GaN (Gallium Nitride) HEMT, while under electrically-active conditions. One of the main issues currently being researched in these devices is their reliability, or their consistent ability to function properly, when subjected to high-power conditions. The researchers of this mechanical study have performed a static (i.e. frequency-independent) reliability analysis using powerful multiphysics computer modeling/simulation to get a better idea of what can cause failure in these devices. Because HEMT transistors are so small (micro/nano-sized), obtaining experimental measurements of stresses and strains during the active operation of these devices is extremely challenging. Physical mechanisms that cause stress/strain in these structures include thermo-structural phenomena due to mismatch in both coefficient of thermal expansion (CTE) and mechanical stiffness between different materials, as well as stress/strain caused by piezoelectric effects (i.e. mechanical deformation caused by an electric field, and conversely voltage induced by mechanical stress) in the AlGaN and GaN device portions (both piezoelectric materials). This piezoelectric effect can be triggered by voltage applied to the device\u27s gate contact and the existence of an HEMT-unique two-dimensional electron gas (2DEG) at the GaN-AlGaN interface. COMSOL Multiphysics computer software has been utilized to create a finite element (i.e. piece-by-piece) simulation to visualize both temperature and stress/strain distributions that can occur in the device, by coupling together (i.e. solving simultaneously) the thermal, electrical, structural, and piezoelectric effects inherent in the device. The 2DEG has been modeled not with the typically-used self-consistent quantum physics analytical equations, rather as a combined localized heat source* (thermal) and surface charge density* (electrical) boundary condition. Critical values of stress/strain and their respective locations in the device have been identified. Failure locations have been estimated based on the critical values of stress and strain, and compared with reports in literature. The knowledge of the overall stress/strain distribution has assisted in determining the likely device failure mechanisms and possible mitigation approaches. The contribution and interaction of individual stress mechanisms including piezoelectric effects and thermal expansion caused by device self-heating (i.e. fast-moving electrons causing heat) have been quantified. * Values taken from results of experimental studies in literatur

GaN Power Devices: Discerning Application-Specific Challenges and Limitations in HEMTs

GaN power devices are typically used in the 600 V market, for high efficiency, high power-density systems. For these devices, the lateral optimization of gate-to-drain, gate, and gate-to-source lengths, as well as gate field-plate length are critical for optimizing breakdown voltage and performance. This work presents a systematic study of lateral scaling optimization for high voltage devices to minimize figure of merit and maximize breakdown voltage. In addition, this optimization is extended for low voltage devices ( \u3c 100 V), presenting results to optimize both lateral features and vertical features. For low voltage design, simulation work suggests that breakdown is more reliant on punch-through as the primary breakdown mechanism rather than on vertical leakage current as is the case with high-voltage devices. A fabrication process flow has been developed for fabricating Schottky-gate, and MIS-HEMT structures at UCF in the CREOL cleanroom. The fabricated devices were designed to validate the simulation work for low voltage GaN devices. The UCF fabrication process is done with a four layer mask, and consists of mesa isolation, ohmic recess etch, an optional gate insulator layer, ohmic metallization, and gate metallization. Following this work, the fabrication process was transferred to the National Nano Device Laboratories (NDL) in Hsinchu, Taiwan, to take advantage of the more advanced facilities there. Following fabrication, a study has been performed on defect induced performance degradation, leading to the observation of a new phenomenon: trap induced negative differential conductance (NDC). Typically NDC is caused by self-heating, however by implementing a substrate bias test in conjunction with pulsed I-V testing, the NDC seen in our fabricated devices has been confirmed to be from buffer traps that are a result of poor channel carrier confinement during the dc operating condition

Gallium nitride-based microwave high-power heterostructure field-effect transistors

The research described in this thesis has been carried out within a joint project between the Radboud Universiteit Nijmegen (RU) and the Technische Universiteit Eindhoven (TU/e) with the title: "Performance enhancement of GaN-based microwave power amplifiers: material, device and design issues". This project has been granted by the Dutch Technology Foundation STW under project number NAF 5040. The aims of this project have been to develop the technology required to grow state-of-the-art AlGaN/GaN epilayers on sapphire and semi-insulating (s.i.) SiC substrates using metal organic chemical vapor deposition (MOCVD) and to fabricate microwave (f > 1 GHz) high-power (Pout > 10 W) heterostructure field-effect transistors (HFETs) on these epitaxial films. MOCVD growth of AlGaN/GaN epilayers and material characterization has been done within the group Applied Materials Science (AMS) of RU. Research at the Opto-Electronic Devices group (OED) of TU/e has focused on both electrical characterization of AlGaN/GaN epilayers and design, process technology development, and characterization of GaN-based HFETs and CPW passive components. Although a considerable amount of work has been done during this research with respect to processing of CPW passive components on s.i. SiC substrates, this thesis focused on active AlGaN/GaN devices only. GaN is an excellent option for high-power/high-temperature microwave applications because of its high electric breakdown field (3 MV/cm) and high electron saturation velocity (1.5 x 107 cm/s). The former is a result of the wide bandgap (3.44 eV at RT) and enables the application of high supply voltages (> 50 V), which is one of the two requirements for highpower device performance. In addition, the wide bandgap allows the material to withstand much higher operating temperatures (300oC - 500oC) than can the conventional semiconductor materials such as Si, GaAs, and InP. A big advantage of GaN over SiC is the possibility to grow heterostructures, e.g. AlGaN/GaN. The resulting two-dimensional electron gas (2DEG) at the AlGaN/GaN heterojunction serves as the conductive channel. Large drain currents (> 1 A/mm), which are the second requirement for a power device, can be achieved because of the high electron sheet densities (> 1 x 1013 cm-2) and high electron saturation velocity. These material properties clearly indicate why GaN is a very suitable candidate for next-generation microwave high-power/high-temperature applications such as high-power amplifiers (HPAs) for GSM base stations, and microwave monolithic integrated circuits (MMICs) for radar systems. In this thesis we have presented the design, technology, and measurement results of n.i.d. AlGaN/GaN:Fe HFETs grown on s.i. 4H-SiC substrates by MOCVD. These devices have submicrometer T- or FP-gates with a gate length (Lg) of 0.7 µm and total gate widths (Wg) of 0.25 mm, 0.5 mm, and 1.0 mm, respectively. The 1.0 mm devices are capable of producing a maximum microwave output power (Pout) of 11.9 W at S-band (2 GHz - 4 GHz) using class AB bias conditions of VDS = 50 V and VGS = -4.65 V. It has to be noted that excellent scaling of Pout with Wg has been demonstrated. In addition, the associated power gain (Gp) ranges between 15 dB and 20 dB, and for the power added efficiency (PAE) values from 54 % up to 70 % have been obtained. These results clearly illustrate both the successful development of the MOCVD growth process, and the successful development and integration of process modules such as ohmic and Schottky contact technology, device isolation, electron beam lithography, surface passivation, and air bridge technology, into a process flow that enables the fabrication of state-of-the-art large periphery n.i.d. AlGaN/GaN:Fe HFETs on s.i. SiC substrates, which are perfectly suitable for application in e.g. HPAs at S-band

STUDY ON THE REDUCTION OF ACCESS RESISTANCE OF INAIN/GAN HIGH ELECTRON MOBILITY TRANSISTORS

Ph.DDOCTOR OF PHILOSOPH

Advanced III-Nitride Technology for mm-Wave Applications

Within wireless communication, there is a continuously growing need for more bandwidth due to an increasing number of users and data intense services. The development within sensor systems such as radars, is largely driven by the need for increased detection range and robustness. In such systems, power amplification and generation at high frequency are of importance. High-electron mobility transistors based on gallium nitride (GaN HEMTs) offer efficient generation of high output power at high frequency. This is enabled by the unique characteristics of GaN and its heterostructures, with a large breakdown field, related to the wide bandgap, and excellent electron transport properties. Due to this, it is today used in high-performing radar, telecommunications, as well as power electronic systems. Despite substantial progress over the last decade, the GaN HEMT is still the subject of intense research to reach its full potential. \ua0Recent development within epitaxy has significantly improved the quality of III-nitride semiconductors, and enabled indium aluminum nitride (InAlN) and InAlGaN as alternatives to AlGaN in the conventional AlGaN/GaN heterostructure. The higher polarization charge in these materials allows for considerable downscaling of the barrier layer thickness with a sustained high sheet carrier density. \ua0This has opened new possibilities for optimization of the high frequency performance. \ua0\ua0In this work, HEMTs with downscaled InAl(Ga)N barrier layers have been developed with the goal to optimize the devices for power amplification in the mm-wave range. Electron trapping and short-channel effects have been addressed in the design of the epi and in the optimization of the process modules. Different surface passivation layers and deposition methods have been evaluated to mitigate electron trapping at the surface. The output power density of a HEMT increased from 1.7 to 4.1 W/mm after passivation with a SiNx layer. The deposition method for Al2O3 passivation layers showed to have a profound impact on the electron trapping. A layer deposited by plasma-assisted atomic layer deposition (ALD) exhibited superior passivation of the surface traps as compared to the layer deposited by thermal ALD, resulting in an output power at 3 GHz of 3.3, and 1.9 W/mm, respectively. The effect of the channel layer thickness (50 – 150 nm) in InAlGaN/AlN/GaN HEMTs with and AlGaN back barrier demonstrated a trade-off between short-channel effects and deep-level electron trapping in the back barrier. The maximum output power was 5.3 W/mm at 30 GHz, obtained for a GaN layer thickness of 100 nm. To further enhance the high frequency performance, the ohmic contacts were optimized by the development of a Ta-based, Au free, metal scheme. Competitive contact resistance of < 0.2 Ωmm was achieved on both AlGaN/GaN and InAlN heterostructures with a Ta/Al/Ta metal stack. The contacts are annealed at a low temperature (550 – 575 \ubaC) compared to more conventional contact schemes, resulting in a smooth morphology and good edge acuity.\ua0 The implementation of microwave monolithic integrated circuits (MMICs) based on III-nitride HEMTs facilitate the use of III-nitride HEMTs in a system where frequency and compactness are key requirements. Thin film resistors (TFRs) are one of the passive components required in MMICs. In this work, a low-resistance titanium nitride (TiN) TFR was developed as a complement to the higher resistance tantalum nitride (TaN) TFR and mesa resistor in the in-house MMIC process. The developed TiN TFR exhibits a sheet resistance of 10 Ω/□, compared to 50 and 200-300 Ω/□ of the TaN TFR and semiconductor resistor, respectively. The critical dissipated power in the TFR showed a correlation to the footprint area, indicating that Joule-heating was the main cause of failure. TiN- and TaN films exhibit different signs of the thermal coefficient of resistance. This feature was used to demonstrate a temperature compensated TFR (TCR = -60 ppm \ubaC) with application in MMICs operating in a wide temperature range

Development of InAlN HEMTs for space application

This thesis investigates the emerging InAlN high electron mobility transistor (HEMT) technology with respect to its application in the space industry. The manufacturing processes and device performance of InAlN HEMTs were compared to AlGaN HEMTs, also produced as part of this work. RF gain up to 4 GHz was demonstrated in both InAlN and AlGaN HEMTs with gate lengths of 1 μm, with InAlN HEMTs generally showing higher channel currents (~150 c.f. 60 mA/mm) but also degraded leakage properties (~ 1 x 10-4 c.f. < 1 x 10-8 A/mm) with respect to AlGaN. An analysis of device reliability was undertaken using thermal stability, radiation hardness and off-state breakdown measurements. Both InAlN and AlGaN HEMTs showed excellent stability under space-like conditions, with electrical operation maintained after exposure to 9.2 Mrad of gamma radiation at a dose rate of 6.6 krad/hour over two months and after storage at 250°C for four weeks. Furthermore a link was established between the optimisation of device performance (RF gain, power handling capabilities and leakage properties) and reliability (radiation hardness, thermal stability and breakdown properties), particularly with respect to surface passivation. Following analysis of performance and reliability data, the InAlN HEMT device fabrication process was optimised by adjusting the metal Ohmic contact formation process (specifically metal stack thicknesses and anneal conditions) and surface passivation techniques (plasma power during dielectric layer deposition), based on an existing AlGaN HEMT process. This resulted in both a reduction of the contact resistivity to around 1 x 10-4 Ω.cm2 and the suppression of degrading trap-related effects, bringing the measured gate-lag close to zero. These discoveries fostered a greater understanding of the physical mechanisms involved in device operation and manufacture, which is elaborated upon in the final chapter

Technology and reliability of normally-off GaN HEMTs with p-type gate

GaN-based transistors with p-GaN gate are commonly accepted as promising devices for application in power converters, thanks to the positive and stable threshold voltage, the low on-resistance and the high breakdown field. This paper reviews the most recent results on the technology and reliability of these devices by presenting original data. The first part of the paper describes the technological issues related to the development of a p-GaN gate, and the most promising solutions for minimizing the gate leakage current. In the second part of the paper, we describe the most relevant mechanisms that limit the dynamic performance and the reliability of GaN-based normally-off transistors. More specifically, we discuss the following aspects: (i) the trapping effects specific for the p-GaN gate; (ii) the time-dependent breakdown of the p-GaN gate during positive gate stress and the related physics of failure; (iii) the stability of the electrical parameters during operation at high drain voltages. The results presented within this paper provide information on the current status of the performance and reliability of GaN-based E-mode transistors, and on the related technological issues