Characterization Of Thermal Stresses And Plasticity In Through-Silicon Via Structures For Three-Dimensional Integration

Through-silicon via (TSV) is a critical element connecting stacked dies in three-dimensional (3D) integration. The mismatch of thermal expansion coefficients between the Cu via and Si can generate significant stresses in the TSV structure to cause reliability problems. In this study, the thermal stress in the TSV structure was measured by the wafer curvature method and its unique stress characteristics were compared to that of a Cu thin film structure. The thermo-mechanical characteristics of the Cu TSV structure were correlated to microstructure evolution during thermal cycling and the local plasticity in Cu in a triaxial stress state. These findings were confirmed by microstructure analysis of the Cu vias and finite element analysis (FEA) of the stress characteristics. In addition, the local plasticity and deformation in and around individual TSVs were measured by synchrotron x-ray microdiffraction to supplement the wafer curvature measurements. The importance and implication of the local plasticity and residual stress on TSV reliabilities are discussed for TSV extrusion and device keep-out zone (KOZ).Microelectronics Research Cente

Three-dimensional integration technology for real time micro-vision system

科研費報告書収録論文(課題番号:06555103・試験研究(B)(1)・H6～H7/研究代表者:小柳, 光正/超高速光バスを有するモンテカルロ解析専用並列処理システムの試作

Copper wafer bonding in three-dimensional integration

Thesis (Ph. D.)--Massachusetts Institute of Technology, Dept. of Electrical Engineering and Computer Science, 2005.Includes bibliographical references (p. 165-176).Three-dimensional (3D) integration, in which multiple layers of devices are stacked with high density of interconnects between the layers, offers solutions for problems when the critical dimensions in integrated circuits keep shrinking. Copper wafer bonding has been considered as a strong candidate for fabrication of three-dimensional integrated circuits (3-D IC). This thesis work involves fundamental studies of copper wafer bonding and bonding performance of bonded interconnects. Copper bonded wafers exhibit good bonding qualities and present no original bonding interfaces when the bonding process occurs at 400⁰C/4000 mbar for 30 min, followed by nitrogen anneal at 400⁰C for 30 min. Oxide distribution in the bonded layer is uniform and sparse. Evolution of microstructure morphologies and grain orientations of copper bonded wafers during bonding and annealing were studied. The bonded layer reaches steady state after post-bonding anneal. The microstructure morphologies and bond strengths of copper bonded wafers under different bonding conditions were investigated.A map summarizing these results provides a useful reference on process conditions suitable for three-dimensional integration based on copper wafer bonding. Similar microstructure morphology of copper bonded interconnects was observed to that of copper bonded wafers. Specific contact resistances of bonded interconnects of approximately 10⁻⁸ [ohms]-cm² were measured by using a novel test structure which can eliminate the errors from misalignment during bonding. The bonding qualities of different interconnect sizes and densities have been investigated. In addition to increasing the bonding temperature and duration, options such as larger interconnect sizes, total bonding area, or use of dummy pads for bonding in the unused area improve the quality of bonded interconnects. Process development of silicon layer stacking based on Cu wafer bonding was successfully applied to demonstrate a strong four-layer-stack structure.Bonded Cu layers in this structure become homogeneous layers and do not show original bonding interfaces. This process can be reliably applied in three-dimensional integration applications.by Kuan-Neng Chen.Ph.D

Investigation into yield and reliability enhancement of TSV-based three-dimensional integration circuits

Three dimensional integrated circuits (3D ICs) have been acknowledged as a promising technology to overcome the interconnect delay bottleneck brought by continuous CMOS scaling. Recent research shows that through-silicon-vias (TSVs), which act as vertical links between layers, pose yield and reliability challenges for 3D design. This thesis presents three original contributions.The first contribution presents a grouping-based technique to improve the yield of 3D ICs under manufacturing TSV defects, where regular and redundant TSVs are partitioned into groups. In each group, signals can select good TSVs using rerouting multiplexers avoiding defective TSVs. Grouping ratio (regular to redundant TSVs in one group) has an impact on yield and hardware overhead. Mathematical probabilistic models are presented for yield analysis under the influence of independent and clustering defect distributions. Simulation results using MATLAB show that for a given number of TSVs and TSV failure rate, careful selection of grouping ratio results in achieving 100% yield at minimal hardware cost (number of multiplexers and redundant TSVs) in comparison to a design that does not exploit TSV grouping ratios. The second contribution presents an efficient online fault tolerance technique based on redundant TSVs, to detect TSV manufacturing defects and address thermal-induced reliability issue. The proposed technique accounts for both fault detection and recovery in the presence of three TSV defects: voids, delamination between TSV and landing pad, and TSV short-to-substrate. Simulations using HSPICE and ModelSim are carried out to validate fault detection and recovery. Results show that regular and redundant TSVs can be divided into groups to minimise area overhead without affecting the fault tolerance capability of the technique. Synthesis results using 130-nm design library show that 100% repair capability can be achieved with low area overhead (4% for the best case). The last contribution proposes a technique with joint consideration of temperature mitigation and fault tolerance without introducing additional redundant TSVs. This is achieved by reusing spare TSVs that are frequently deployed for improving yield and reliability in 3D ICs. The proposed technique consists of two steps: TSV determination step, which is for achieving optimal partition between regular and spare TSVs into groups; The second step is TSV placement, where temperature mitigation is targeted while optimizing total wirelength and routing difference. Simulation results show that using the proposed technique, 100% repair capability is achieved across all (five) benchmarks with an average temperature reduction of 75.2? (34.1%) (best case is 99.8? (58.5%)), while increasing wirelength by a small amount

Three Dimensional Integration (3DI) of semiconductor circuit layers: new devices and fabrication process

The device density of Integrated Circuits (ICs) manufactured by current VLSI technology is reaching it\u27s theoretical limit. Nevertheless, the demand for integration of more devices per chip is growing. To accommodate this need three main possibilities can be explored: Wafer Scale Integration (WSI), Ultra Large Scale Integration (ULSI), and Three Dimensional Integration (3DI). A brief review of these techniques along with their comparative advantages and disadvantages is presented. It has been concluded that 3DI technology is superior to others. Therefore, an attempt is made to develop a viable fabrication process for this technology. This is done by first reviewing the current technologies that are utilized for fabrication of Integrated Circuits (ICs) and their compatibility with 3DI stringent requirements.;Based on this review, a set of fabrication procedure for realization of 3DI technology, are presented in chapter 3. In Chapter 1 the compatibility of the currently used devices, such as BJTs and FETS, with 3DI technology is examined. Moreover, a new active device is developed for 3DI technology to replace BJTs and FETs in circuits. This new device is more compatible to the constrains of 3DI technology. Chapter 2 is devoted to solving the overall problems of 3DI circuits. The problem of heat and power dispassion and signal coupling (Cross-Talk) between the layers are reviewed, and an inter-layer shield is proposed to overcome these problems. The effectiveness of such a thin shield is considered theoretically. In Chapter 3 a fabrication process for 3DI technology is proposed. This is done after a short analysis of previous attempts in developing 3DI technologies.;Chapter 4 focuses on analog extension of 3DI technology. Moreover, in this chapter microwave 3DI circuits or 3DI MMIC is investigated. Practical considerations in choice of material for the proposed device is the subject of study in Chapter 5. Low temperature ohmic contact and utilization of metal-silicides for the proposed device are considered in this chapter. Finally in Chapter 6 various computer verifications for this work is presented, and in Chapter 7 experimental results to support this work is included

Three-dimensional Integration of Compute Core and I/O in High-performance ASIC

In certain ASICs, the input-output (I/O) interfaces, such as high-bandwidth memory (HBM) physical layer (PHY), serdes, etc., occupy substantial area on the die. Validation of I/O interfaces fabricated in recent process nodes, e.g., 3 nm technology, is generally more involved and has corresponding time to market costs. For high-performance ASICs whose compute function is divided amongst cores, communications between an HBM and the core farthest from it can be complex. This disclosure describes techniques to partition the compute cores and the I/O interface into separate dies and to implement these in suitable process nodes which may be different, e.g., compute core in 3 nm technology and I/O interface in 7 nm technology. By doing so, the time to validate the I/O interface is reduced. Additionally, communication lines between an HBM and a compute core far away from each other are simplified. Another benefit is that the area of compute core dies can be maximized due to no other I/Os

Multiscale microstructures and microstructural effects on the reliability of microbumps in three-dimensional integration

The dimensions of microbumps in three-dimensional integration reach microscopic scales and thus necessitate a study of the multiscale microstructures in microbumps. Here, we present simulated mesoscale and atomic-scale microstructures of microbumps using phase field and phase field crystal models. Coupled microstructure, mechanical stress, and electromigration modeling was performed to highlight the microstructural effects on the reliability of microbumps. The results suggest that the size and geometry of microbumps can influence both the mesoscale and atomic-scale microstructural formation during solidification. An external stress imposed on the microbump can cause ordered phase growth along the boundaries of the microbump. Mesoscale microstructures formed in the microbumps from solidification, solid state phase separation, and coarsening processes suggest that the microstructures in smaller microbumps are more heterogeneous. Due to the differences in microstructures, the von Mises stress distributions in microbumps of different sizes and geometries vary. In addition, a combined effect resulting from the connectivity of the phase morphology and the amount of interface present in the mesoscale microstructure can influence the electromigration reliability of microbumps