Enhanced doping efficiency of ultrawide bandgap semiconductors by metal-semiconductor assisted epitaxy
11876147 ยท 2024-01-16
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Inventors
Cpc classification
International classification
H01L33/00
ELECTRICITY
H01L33/06
ELECTRICITY
Abstract
An epitaxial growth process, referred to as metal-semiconductor junction assisted epitaxy, of ultrawide bandgap aluminum gallium nitride (AlGaN) is disclosed. The epitaxy of AlGaN is performed in metal-rich (e.g., Ga-rich) conditions using plasma-assisted molecular beam epitaxy. The excess Ga layer leads to the formation of a metal-semiconductor junction during the epitaxy of magnesium (Mg)-doped AlGaN, which pins the Fermi level away from the valence band at the growth front. The Fermi level position is decoupled from Mg-dopant incorporation; that is, the surface band bending allows the formation of a nearly n-type growth front despite p-type dopant incorporation. With controlled tuning of the Fermi level by an in-situ metal-semiconductor junction during epitaxy, efficient p-type conduction can be achieved for large bandgap AlGaN.
Claims
1. A method of fabricating a device, the method comprising: using molecular beam epitaxy (MBE), depositing a p-type dopant, Group III elements, and a Group V element in a first layer above a substrate; and forming a liquid metal layer on a growth interface of the first layer while the p-type dopant, the Group III elements, and the Group V element are being deposited in the layer, wherein the liquid metal layer is smooth and conformal across the first layer throughout said forming.
2. The method of claim 1, wherein: said depositing comprises depositing magnesium (Mg), aluminum (Al), gallium (Ga), and nitrogen (N) in the first layer, to form by epitaxy a Mg-doped AlGaN layer; and said forming comprises forming a liquid Ga layer on the Mg-doped AlGaN layer, wherein the liquid Ga layer causes formation of a metal-semiconductor junction during epitaxy of the Mg-doped AlGaN layer, and wherein the liquid Ga layer is smooth and conformal across the first layer throughout said forming.
3. The method of claim 2, further comprising, during the epitaxy of the Mg-doped AlGaN layer, controlling the Al composition by tuning Al flux and growth rate with N flow rate and allowing excess Ga to form a liquid metal layer on the surface of the Mg-doped AIGaN.
4. The method of claim 2, wherein the Mg-doped AlGaN layer comprises a portion of a light emitting diode (LED) heterostructure, wherein the LED heterostructure further comprises a silicon-doped AlGaN layer, a plurality of (Al)GaN quantum wells, and a p-doped contact layer.
5. The method of claim 2, further comprising, before the epitaxy of the Mg-doped AlGaN layer: forming one or more layers over the substrate, wherein the one or more layers are selected from the group consisting of: an undoped AlN buffer layer; an undoped GaN layer; a doped GaN layer; an undoped AlGaN layer; and a doped AlGaN layer.
6. The method of claim 2, wherein the liquid Ga layer has a thickness of not less than five nanometers.
7. The method of claim 2, wherein the Al content in the Mg-doped AlGaN layer is at least 60 percent.
8. The method of claim 7, wherein the Mg-doped AlGaN layer has a free hole concentration of 4.510.sup.17 per cubic centimeter with an Al content of 90 percent.
9. The method of claim 1, wherein the MBE is selected from the group consisting of: plasma-assisted MBE; and ammonia-based MBE.
10. The method of claim 1, further comprising: depositing a buffer layer on the substrate; forming an undoped aluminum (Al), gallium (Ga), and nitrogen (N) layer on the buffer layer; and forming a doped AlGaN layer on the undoped AlGaN layer.
11. A method of fabricating a device, the method comprising: forming a buffer layer over a substrate; forming an undoped aluminum gallium nitride (AlGaN) layer over the buffer layer; and forming one or more layers above the undoped AlGaN layer, the one or more layers comprising a magnesium (Mg)-doped AlGaN layer and a p-doped contact layer, wherein the Mg-doped AlGaN layer is formed by: depositing Mg, Al, Ga, and N in a layer using molecular beam epitaxy (MBE), wherein excess Ga is provided during said depositing and forms a liquid Ga layer on the Mg-doped AlGaN layer, wherein the liquid Ga layer causes formation of a metal-semiconductor junction during epitaxy of the Mg-doped AlGaN layer, and wherein the liquid Ga layer is smooth and conformal across the Mg-doped AlGaN layer throughout said depositing.
12. The method of claim 11, further comprising, during the epitaxy of the Mg-doped AlGaN layer, controlling the Al composition by tuning Al flux and growth rate with N flow rate, to allow excess Ga to form a liquid metal layer on the surface of the Mg-doped AlGaN.
13. The method of claim 11, wherein the MBE is selected from the group consisting of: plasma-assisted MBE; and ammonia-based MBE.
14. The method of claim 11, wherein the Mg-doped AlGaN layer comprises a portion of a light emitting diode (LED) heterostructure, wherein the LED heterostructure further comprises a silicon (Si)-doped AIGaN layer and a plurality of (Al)GaN quantum wells.
15. The method of claim 14, further comprising forming metal contacts on the Si-doped AlGaN layer.
16. The method of claim 11, further comprising forming a metal contact on the Mg-doped AlGaN layer.
17. The method of claim 11, further comprising forming a metallic contact on the p-doped contact layer.
18. The method of claim 11, wherein the liquid Ga layer has a thickness of not less than five nanometers.
19. The method of claim 11, wherein the Al content in the Mg-doped AlGaN layer is at least 60 percent.
20. The method of claim 19, wherein the Mg-doped AlGaN layer has a free hole concentration of 4.510.sup.17 per cubic centimeter with an Al content of 90 percent.
Description
BRIEF DESCRIPTION OF DRAWINGS
(1) The accompanying drawings, which are incorporated in and form a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention. Like numbers denote like elements throughout the drawings and specification. The figures may not be drawn to scale.
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DETAILED DESCRIPTION
(18) Reference will now be made in detail to the various embodiments of the present disclosure, examples of which are illustrated in the accompanying drawings. While described in conjunction with these embodiments, it will be understood that they are not intended to limit the disclosure to these embodiments. On the contrary, the disclosure is intended to cover alternatives, modifications and equivalents, which may be included within the spirit and scope of the disclosure. Furthermore, in the following detailed description of the present disclosure, numerous specific details are set forth in order to provide a thorough understanding of the present disclosure. However, it will be understood that the present disclosure may be practiced without these specific details. In other instances, well-known methods, procedures, components, and circuits have not been described in detail so as not to unnecessarily obscure aspects of the present disclosure.
(19) Some portions of the detailed descriptions that follow are presented in terms of procedures, logic blocks, processing, and other symbolic representations of operations for fabricating devices such as semiconductor devices. These descriptions and representations are the means used by those skilled in the art of device fabrication to most effectively convey the substance of their work to others skilled in the art. In the present application, a procedure, logic block, process, or the like, is conceived to be a self-consistent sequence of steps or instructions leading to a desired result. The steps are those requiring physical manipulations of physical quantities. It should be borne in mind, however, that all of these and similar terms are to be associated with the appropriate physical quantities and are merely convenient labels applied to these quantities. Unless specifically stated otherwise as apparent from the following discussions, it is appreciated that throughout the present application, discussions utilizing terms such as epitaxy, depositing, forming, varying, removing, incorporating, or the like, refer to actions and processes of device fabrication.
(20) Operations described as separate blocks may be combined and performed in the same process step (that is, in the same time interval, after the preceding process step and before the next process step). Also, some of the operations may be performed in a different order than the order in which they are described below. Furthermore, fabrication processes and steps may be performed along with the processes and steps discussed herein; that is, there may be a number of process steps before, in between, and/or after the steps shown and described herein. Importantly, embodiments according to the present invention can be implemented in conjunction with these other (perhaps conventional) processes and steps without significantly perturbing them. Generally speaking, embodiments according to the present invention can replace or be integrated with portions of a conventional process without significantly affecting peripheral processes and steps.
(21) It is understood that the figures are not necessarily drawn to scale, and only portions of the devices and structures depicted, as well as the various layers that form those structures, are shown. For simplicity of discussion and illustration, the process is described for one or two devices or structures, although in actuality more than one or two devices or structures may be formed.
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(24) In block 104 of
(25) In block 104 of
(26) More specifically, during the epitaxy of the Mg-doped AlGaN layer 204, the Al composition is controlled by tuning Al flux and growth rate with N flow rate. For example, the flow rate of the N can be held constant, while the Al flux can be tuned to adjust the composition of the alloy. As AlN forms preferentially over GaN in the Mg-doped AlGaN layer, this results in an accumulation of a portion of the Ga to form the liquid Ga layer 206 on the Mg-doped AlGaN layer. In an embodiment, the flow rate of the nitrogen is 0.4 standard cubic centimeters per minute; however, the invention is not so limited and different flow rates can be used. In an embodiment, the Mg-doped AlGaN layer 204 is grown at a temperature of approximately 700 C.; however, the invention is not so limited, and the Mg-doped AlGaN layer can be grown in a broad range of temperatures.
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(28) In embodiments according to the present invention, the formation of the metal-semiconductor junction during epitaxy pins the Fermi level away from the valence band at the growth front, as shown in
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(30) Mg incorporation in AlGaN is enhanced by nearly one order of magnitude compared to a conventional growth process. For example, an Mg concentration of approximately 210.sup.20 cm.sup.3 was measured in Al.sub.0.75Ga.sub.0.25N for a moderate Mg flux of approximately 710.sup.8 Torr. A significant reduction of carbon impurity incorporation was also confirmed through detailed secondary ion mass spectrometry (SIMS) measurements. Significantly, a free hole concentration of approximately 4.510.sup.17 cm.sup.3 was measured for Al.sub.0.9Ga.sub.0.1N, with resistivity values less than five .Math.cm, which is nearly three orders of magnitude lower compared to conventional techniques.
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(32) In block 602 of
(33) In block 604, in an embodiment, an undoped AlGaN layer 505 is formed over the AlN buffer layer 503.
(34) In the embodiment of
(35) In an embodiment, the heterostructure 506 consists of a 250 nm thick Si-doped Al.sub.0.7Ga.sub.0.3N layer, multiple Al.sub.0.45Ga.sub.0.55N/Al.sub.0.7Ga.sub.0.3N quantum wells, a 60 nm thick Mg-doped AlGaN layer, and a three nm p-GaN contact layer. In an embodiment, the first (lower) half (e.g., the first 30 nm) of the Mg-doped AlGaN layer is graded from an Al composition of approximately 70% to 50% to make use of polarization-induced doping to maximize hole injection into the active region, and the second (upper) half (e.g., the second 30 nm) of that layer is Mg-doped Al.sub.0.5Ga.sub.0.5N. In an embodiment, an AlGaN electron blocking layer (not shown) is also incorporated to reduce electron overflow.
(36) In an embodiment, the device active region is calibrated for emission at approximately 280 nm.
(37) Continuing with reference to
(38) In block 610, portions of the heterostructure 506 (e.g., portions of the p-doped (Al)GaN contact layer 511, Mg-doped AlGaN layer 204, and (Al)GaN quantum wells 509) that are not covered by the metallic contact 513 are removed. For other types of devices, other layers of the heterostructure 506 can be removed.
(39) In block 612, a metal layer is deposited in locations where the p-doped (Al)GaN contact layer 511, Mg-doped AlGaN layer 204, and quantum wells 509 are removed to form contacts 515 on the Si-doped AlGaN layer 507. In an embodiment, the metal layer includes titanium (Ti); however, the invention is not so limited.
(40) In embodiments, an ultraviolet (UV) light emitting diode (LED) fabrication process includes the use of photolithography, dry etching, and contact metallization techniques. The device mesa has an area 50 m50 m. A Ti (40 nm)/Al (120 nm)/Ni (40 nm)/Au (50 nm) metal stack is deposited on n-AlGaN and annealed at 750 C. for 30 seconds in nitrogen ambient to form a n-metal contact. A Ni (20 nm)/Al (100 nm)/Au (20 nm) metal stack is deposited on p-AlGaN and annealed at 500 C. for five minutes in air to form a p-metal contact.
(41) With reference now to the embodiment of
(42) In block 616, the p-doped contact layer 511 (e.g., a p-doped GaN or AlGaN contact layer) is formed on the Mg-doped AlGaN layer 204.
(43) In block 618, the metallic (ohmic) contact 513 is formed on the p-doped (Al)GaN contact layer 511.
(44) In block 620, a contact 515 is formed on the Mg-doped AlGaN layer 204.
(45) More specifically, in embodiments, for a Schottky diode 510 fabricated on the Mg-doped AlGaN layer 204, a metallic stack consisting of Ni (20 nm)/Al (100 nm)/Au (20 nm) is first deposited for the ohmic contact 513 and annealed at 500 C. for five minutes in the presence of air. The p-doped (Al)GaN layer 511 that was outside of the Ni/Al/Au metallic contact 513 is removed using a low-power plasma etch with BCl.sub.3/Cl.sub.2 chemistry. Then, a 200 nm thick Ti layer is deposited for the Schottky contact 515. In an embodiment, the area of the diode is 500 m500 m.
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(48) Also, the carbon (C)-impurity concentration was significantly reduced using metal-semiconductor junction assisted epitaxy compared to metal-organic chemical vapor deposition (MOCVD). For the sample grown using metal-semiconductor junction assisted epitaxy, the carbon concentration is limited by the measurement background of SIMS (approximately 110.sup.16 cm.sup.3). For comparison, carbon concentrations of approximately 510.sup.16 cm.sup.3 to 210.sup.18 cm.sup.3 have been commonly measured in Al-rich AlGaN grown by MOCVD.
(49) The pinning of the Fermi level at the growth front through metal-semiconductor junction assisted epitaxy also leads to a significant decrease in the formation of point defects, which explains the observation that undoped (Al)GaN layers grown under Ga-rich conditions show approximately three orders of magnitude higher resistivity compared to films grown under conventional conditions.
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(52) Thus, the significantly enhanced Mg dopant incorporation can lead to the formation of an impurity band for hole hopping conduction, but more importantly, results in substantially reduced activation energies for a portion of Mg-dopants, thereby enabling the presence of large hole carrier concentrations at room temperature in AlGaN, that were not possible otherwise.
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(54) Metal-semiconductor junction assisted epitaxy was used to grow a series of Mg-doped samples with Al compositions varying from approximately 75% up to approximately 90%. Atomic force microscopy measurements indicated a smooth surface with roughness less than one nm for all the samples. Hall measurements were performed on the samples, using the van der Pauw method, to determine the hole concentration, hole mobility, and resistivity of the AlGaN layers for temperatures ranging from room temperature to 500 C. The room temperature hole concentration is observed to monotonically decrease with increasing Al content, illustrated in
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(56) The resistivity values of some previously reported Mg-doped AlGaN layers are plotted versus Al compositions in
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(58) With reference to
(59) The measured hole mobility, shown in
(60) The resistivity, shown in
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(62) The significantly reduced resistivity of Mg-doped AlGaN, enabled by metal-semiconductor junction assisted epitaxy, is important to improve the efficiency of optoelectronic devices operating in the mid and deep UV wavelengths. The device characteristics of AlGaN UV LEDs, emitting at approximately 280 nm, grown using metal-semiconductor junction assisted epitaxy, were compared with the device characteristics of identical LEDs grown using conventional epitaxy.
(63) A typical electroluminescence spectrum is shown in
(64) As shown in
(65) In summary, by tuning the surface Fermi level using metal-semiconductor junction assisted epitaxy, efficient p-type conduction can be achieved for Al-rich AlGaN that was not previously possible. The presence of a metal-semiconductor interface at the growth front pins the Fermi level away from the valence band edge, which can significantly enhance Al(Ga)-substitutional Mg-dopant incorporation and further reduces the formation of compensating point defects. The presence of surface states, which are strongly affected by growth conditions as has been previously described for both polar and non-polar surfaces, may further play a role in pinning the Fermi level away from the valence band, although the surface state density structure at the elevated temperatures required for crystal growth has remained unknown. As such, large concentrations of Mg-acceptors can be incorporated in Al-rich AlGaN, which enables the formation of a Mg impurity band. Al-rich AlGaN epilayers, with resistivity values below one .Math.cm for Al.sub.0.75Ga.sub.0.25N and approximately four .Math.cm for Al.sub.0.9Ga.sub.0.1N, have been measured, which are essential for achieving high efficiency mid and deep UV optoelectronic devices. Deep UV LEDs grown using metal-semiconductor junction assisted epitaxy show a great improvement in external quantum efficiency, and lower turn-on voltage, as compared to devices grown using conventional epitaxy. Metal-semiconductor junction assisted epitaxy can be further extended for the epitaxy/synthesis of a broad range of semiconductor nanostructures and heterostructures to achieve controlled dopant incorporation and to fundamentally improve their structural, electronic, and optical properties.
(66) The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the invention and its practical application, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims appended hereto and their equivalents.