Iridium etching for FeRAM applications

1. A method of etching an iridium layer for use in a ferroelectric device, comprising:

preparing a substrate;

depositing a barrier layer on and in contact with the substrate;

depositing an iridium layer on the barrier layer;

depositing a layer of TiN over the iridium layer as a replacement gate;

etching a portion of the iridium/TiN stack;

depositing a layer of TEOS over the remaining iridium/TiN stack;

polishing to remove the TEOS layer to the level of the upper surface of the TIN layer;

etching to remove the TiN layer;

depositing a hard mask layer on and in contact with the iridium layer;

depositing, patterning and developing a photoresist layer on the hard mask;

etching the hard mask layer;

etching the iridium layer using argon, oxygen and chlorine chemistry in a high-density plasma reactor; and

depositing a layer of ferroelectric material in place of the removed TiN;

completing the ferroelectric device.

2. The method of claim 1 wherein said etching the iridium layer includes a gas chemistry mixture of Ar, O 2 , and a chlorine containing gas taken from the group of chlorine-containing gases consisting of Cl 2 , BCl 3 , CCl 4 , SiCI 4 , and their combinations, wherein the percentage of the oxygen in the gas chemistry is in the range of between about 5% to 50% , the percentage of argon in the gas chemistry is in the range of between about 20% to 50% , and wherein the remaining gas in the chemistry is the chlorine-containing gas; at a total gas flow rate of between about 40 sccm to 70 sccm, a process pressure of between about 3 mtorr. to 10 mtorr.

3. The method of claim 2 wherein the microwave power in the reactor is between about 400 W to 1000 W, the substrate RF bias power is between about 10 W to 1000 W, and the substrate temperature is between about −50° C. to 500° C.

4. The method of claim 1 wherein said preparing the substrate includes preparing a substrate taken from the group of substrates consisting of conventional silicon, bulk silicon, silicon dioxide, and polysilicon substrate.

5. The method of claim 1 wherein said depositing a barrier layer includes depositing a layer of material taken from the group of materials consisting of Ta, TaN, Ti, TiN, TiAIN, TaAlN, TiSiN, TaSiN, TiAI, and TiAlN, to a thickness of between about 10 nm to 100 nm.

6. The method of claim 1 wherein said depositing an iridium layer includes depositing a layer of iridium to a thickness of between about 30 rim to 500 rim.

7. The method of claim 1 wherein said depositing a hard mask includes depositing a layer of material taken from the group of materials consisting of TiN, TiO 2 , Ta, TaN, TiAIN, TaAlN, TiSiN, TaSiN, TiAl, and TiAlN, to a thickness of between about 10 rim to 30 rim.

8. The method of claim 1 wherein said completing the ferroelectric device includes depositing a ferroelectric layer taken from the group of ferroelectric materials consisting of PGO and doped PGO.

9. The method of claim 1 which includes, after said depositing a barrier layer, depositing an adhesive layer before said depositing an iridium layer, wherein the adhesive layer includes depositing a layer of Ti.

10. A method of etching an iridium layer for use in a ferroelectric device, comprising:

preparing a substrate;

depositing a barrier layer on the substrate;

depositing an iridium layer on the barrier layer;

depositing a layer of TiN over the iridium layer, forming an iridiuim/TiN stack, as a replacement gate;

depositing a hard mask layer on the iridium layer;

depositing, patterning and developing a photoresist layer on the hard mask;

etching the hard mask layer;

etching a portion of the iridium/TiN stack;

depositing a layer of TEOS over the remaining iridium/TiN stack;

polishing to remove the TEOS layer to the level of the upper surface of the TiN layer;

etching to remove the TiN layer;

depositing a layer of ferroelectric material in place of the removed TiN;

etching the iridium layer using argon, oxygen and chlorine chemistry in a high-density plasma reactor; and

completing the ferroelectric device.