Professional Documents
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SEMICONDUCTOR
RESEARCH
Toh-Ming Lu
Citation: Lu, Toh-Ming (2023). My road to semiconductor research. In: "Evolutionary Progress
in Science, Technology, Engineering, Arts and Mathematics", Wang, Lawrence K. and Tsao,
Hung-ping (Editors). Volume 5, Number 8A, 5(8A), August 1, 2023, 33 pages. Lenox
Institute Press, Auburndale, Massachusetts, USA. Lenox.Institute@gmail.com; lut@rpi.edu.
https://doi.org/10.17613/71gt-h283
My Road to Semiconductor Research
Toh-Ming Lu
i
Abstract
This electronic book is a memoir recalling how I entered semiconductor
research and how I got involved in the US semiconductor research
consortium called “Semiconductor Research Corporation (SRC)”. In the
late 1990’s I became the director of “Center for Advanced Interconnect
Science and Technology” funded by SRC. The Center involved 15
universities, 30 faculty, and 40 graduate students doing advanced
interconnect research. SRC member companies include Intel, IBM, AMD,
TI, UMC (Taiwan), Chartered Semiconductor Manufacturing (Singapore).
The Center produced over 100 PhD students who later played leadership
roles in semiconductor industry. In 2004, Novellus Systems, a major
semiconductor manufacturing equipment company, donated a Cu
deposition system to Fudan University in anticipation of future business
in China. The company organized a workshop in Shanghai. I highlighted
some of the activities. I also described some international students
graduated from my group, in particular, the interesting and unusual
educational and career paths of some Chinese graduate students, who
eventually served semiconductor industry. Some future possibilities
beyond the current Si technology are also briefly discussed.
ii
Key words: vacuum tubes, semiconductor transistors, integrated circuits,
interconnect, Semiconductor Research Corporation, Novellus Systems,
beyond Si technology, quantum physics, quantum computing.
iii
Bio sketches
Dr. Toh-Ming Lu was born in Sibu, Sarawak,
Malaysia in 1944. He earned a BS degree in
physics in 1968 from Cheng Kung
University, Tainan, Taiwan and a PhD degree
in physics in 1976 from University of
Wisconsin, Madison.
His research interest has been in the area of semiconductors for advanced
electronics and energy applications. His honors include Materials
Research Society Medal Award in 2004 and Semiconductor Research
Corporation Faculty Leadership Award in 2015. He is Fellow of four
major societies: American Physical Society, American Vacuum Society,
American Association for the Advancement of Sciences, and the Materials
Research Society.
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Table of contents Page
Chapter 1. Introduction 1
1-1. Materials discoveries and advancement of civilization 1
1-2. Vacuum tubes 2
1-3. Semiconductor transistors 4
1-4. Technology nodes 6
1-5. Integrated circuits 7
v
3-3. Visiting SMIC 22
vi
My Road to Semiconductor Research
Chapter 1. Introduction
1-1. Materials discoveries and advancement of civilization
Throughout human history, materials discoveries and usage play a key
role in the advancement of civilization. In the Bronze Age (3000 BC), the
developing of copper, with cast tools and weapons, was a key factor
leading to urbanization. The development of iron tools (1200 BC) led to
the agriculture society. The use of coal sparked the steam engine invention
(1720). This was the first industrial revolution. The utilization of oil (1864)
led to the second industrial revolution with the invention of automobile
and heavy machinery. The use of “man-made” quantum materials,
semiconductors (1945), steered the third industrial revolution where
modern information technology is based on.
1
“integrated circuits”. Integrated circuits are the foundation of modern
computers, cell phones, etc.
(a) (b)
https://www.engineering.com/story/vacuum-tubes-the-world-before-transistors.
Fig. 1-1(a). Schematic of a vacuum tube amplifier. Fig.1-1(b). A real vacuum tube
device.
The vacuum tube contains three components: cathode, control grid, and
anode. Cathode is a filament where electrons can be generated simply by
heating it (passing a current through it). Electrons are emitted from the
cathode. An input bias is applied to the control grid to attract electrons.
2
The control grid is placed between the cathode and anode. The grid has
holes that allow elections to pass through. By adjusting the voltage
applied to the grid, you can control the number of electrons flowing from
the cathode to the anode. The more you increase the grid voltage, the more
electrons can pass through it, and the higher the anode current. This is the
amplification effect of a triode. The triode can serve as a signal amplifier
as well as an on/off switch.
3
Semiconductor transistors
https://en.wikipedia.org/wiki
/Field-effect transistor
Fig. 1-3. Inventors of transistor:
Fig. 1-2. Schematic of a Bardeen-Shockley-Brattain (1948).
Metal-oxide-semiconductor transistor.
This is where quantum physics comes into play. Without going into detail,
for our purpose, quantum effect can create a conduction path between the
4
source and drain and let the electrons passing through the narrow channel
in between the insulator (oxide) and the semiconductor when a bias is
applied at the gate.
5
surrounding the inner trench (see the schematic in Fig. 1-4). More charge
can be accumulated in the capacitor to increase the performance of the
memory.
6
1-4. Integrated circuits (ICs)
https://www.wellpcb.com/i
ntegrated-circuits.html
Fig. 1-5. Left: single transistor. Middle: integrated chip with billions of transistors. Right:
combined with other functional chips Such as memory chip to form a final product.
Fig. 1-5 illustrates how the transistors are integrated to form the final
product. Semiconductor industry was created in the 1960s and 1970s: in
Japan, there were Toshiba, Fujitsu, NEC, Hitachi, and in the US, we have
TI, Intel, Fairchild, AMD, Motorola. Applications include computers,
mobile devices, etc.
7
Chapter 2. On the road to semiconductor research
2-1. Interviewing at Rensselaer Polytechnic Institute
In the spring of 1982. I was interviewed for a junior
faculty position at the Center for Integrated
Electronics, Rensselaer Polytechnic Institute, Troy,
NY. This was a newly created Center and Dr. Andy
Steckl was the Center Director. (See Fig. 2-1). Dr.
Fig. 2-1. Dr. Andy
Steckl
Steckl is now a professor at The University of
Cincinnati.
At that time, I had an offer from another school. Dr. Steckl was very
persuasive. He argued that semiconductors would have the most impact
on life and everything. It was the main-stream technology with the largest
employment for science and engineering students. But there was an
opposite view from my mentor back in Wisconsin, “Why into
semiconductors? US semiconductor industry like US steel, was going to
be taken over by Japan.” Indeed, this was absolutely true. At that time,
Japanese semiconductor products dominated the worldwide market with
their superior manufacturing capability.
8
To compete with the Japanese manufacturing, the US semiconductor
companies got together and formed a consortium called “Semiconductor
Research Corporation (SRC)”. Each company contributed funds to the
consortium based on the company’s sales. The money was distributed to
US universities to conduct research that was relevant to the needs of
semiconductor manufacturing. In addition to the research targets, the most
important goal was to produce semiconductor manufacturing workforce.
That included advanced degrees in semiconductor manufacturing. SRC
was like a funding agency similar to that of government funding agencies
such as National Science Foundation, The Air Force Office of Scientific
Research, The Office of Naval Research, Army Research Office, and
Defense Advanced Research Projects Agency (DARPA), where faculty in
the US universities could submit proposals that were relevant to
semiconductor manufacturing. SRC was eventually turned into GRC
(Global Research Corporation) that included some international
semiconductor companies.
In 1982, my first research contract was from SRC. A few years later, I was
invited to give a talk at a semiconductor related conference in Washington
DC. The room was dark, when I walked into the room, there were over
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700 people in the audience. This was a shock to me. Before that I was
doing surface physics research. When I gave a talk at surface physics
related conference, there were at most 30 to 40 people in the audience. I
then began to fully understand and appreciated what Dr. Steckl’ mean by
“main-stream technology”.
Each year, SRC held a conference for students and faculty to present their
research results in front of the scientists and engineers represented by the
companies known as the industry liaisons. It was also a forum for SRC
member companies to meet students for potential employment. SRC also
invited prominent speakers to address the future of semiconductor
industry. I remember one year, SRC invited a prominent economist, Lester
Thurow (see Fig. 2-2), Dean of the MIT Sloan School of Management to
give a talk on the competitiveness of semiconductor industry between the
US and Japan. His conclusion was dire. He argued how Japanese
semiconductor manufacturing was unbeatable. That did not bode well
with the organizer and the audience, of course.
Remember, the purpose of SRC was to compete
with Japan. Note that SRC excluded Japanese
Fig. 2-2. Dr. Lester Thurow
companies to join as members.
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2-2. The Plaza Accord
Actually, the debate was not confined to
the SRC meetings. SRC member
companies as a group held many
meetings with government agencies to
https://en.wikipedia.org/wiki/
produce strategies to help the US Plaza_Accord
Fig. 2-3. The Plaza Accord
semiconductor industry to compete with meeting.
The net result was the 1985 Plaza Accord (see Fig. 2-3) for government’s
currency intervention. James Baker III represented the US and Noboru
Takeshita represented Japan. The joint agreement was signed by France,
Germany, Japan, and the US to depreciate the US dollar relative to the
French franc, German mark, British pound, and Japanese yen. In addition,
the US placed a heavy duty on Japanese high end semiconductor products
(for example, 100 % tax for Toshiba’s products). This was the beginning
of the end of free market that we knew of.
11
The 1985 Plaza Accord had led to the domination of the US
semiconductor industry. For the hardware, the US had TI, Motorola, Intel,
Micron, AMD, and for the software the US had Microsoft.
2-3. Interconnect research
Now let me describe a bit what we were doing
in research. In addition to my semiconductor
devices research (including solar cell
research), I was heavily involved in on-chip
wiring research. The devices built on a Si chip
need to communicate to the outside world
through wiring on the chip. This wiring is
called “interconnect”. Fig. 2-4 illustrates the
idea. The brown color represents Cu lines. https://en.wikipedia.org/wiki/Bac
k_end_of_line#/media/File:Cmos-
Near the bottom of devices, the density of chip_structure_in_2000s_(en).svg
interconnect is high due to the small size Fig. 2-4. A cross section of
multilevel chip interconnect.
devices. The interconnect density decreases
going up in the chip. A key research is on the materials used in the
interconnect. For many decades, Aluminum (Al) was the material of
choice due to its incredible air stability. Al is very easily oxidized when it
is exposed to air to form a very thin layer of stable Aluminum oxide. This
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layer of oxide would protect Al from further oxidation. The household use
of Al foil is an example. It is shiny even after exposing in the ambient air
for a long time. However, Al has a relatively high resistivity compared
with some other metals which would slow down the speed of the chip.
Figure 2-5 (left) shows the response of a step-like signal to the capacitor-
resistor system. The graph represents an on-off switch of the device. The
width of the curve is approximately equal to the product of resistance R
and capacitance C. This on-off switch represents a “bit” of information.
Figure 2-5 (right) shows a sequence of bits during the operation. The
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speed of the circuit is defined as the number of bits per second. If two
adjacent bits are too close, then the bits overlap, and one cannot resolve
Fig. 2-5. Left: the response of a sharp input signal of a resistance-capacitor system.
Right: repeated on-off signals (bits) of a resistance-capacitance system.
Note that the definition of speed here is different than the usual definition
of speed of an object which is defined as the distance travelled in a unit
of time, meter per second. It describes how fast an object travels. The
electromagnetic signal travels in vacuum are 3 108 meters per second.
The signal travels in a circuit are slower than that in vacuum. But it is still
very fast. This is not the limit of the operation of a circuit.
Therefore, the sharper the response signal, the faster the speed. To achieve
a sharper response, one needs a smaller value of RC. The goal of
improving the speed is therefore to reduce the RC delay. To reduce the R
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value, one can choose a lower resistance metal. To reduce the capacitance,
one needs to choose a low dielectric constant dielectric material. The
lowest dielectric material is air which has a dielectric constant of 1. But
air is not realistic because it cannot separate the metal lines. The next best
thing is a porous dielectric material which is what many companies use.
For metals, our research had been to explore the feasibility of using Cu or
silver (Ag) as the interconnect material for their lower resistivity
compared to that of Al. This had been a challenging topic because Cu and
Ag are corrosive, and they need to be protected. We finally focused on Cu.
Actually, my favorite metal was Ag, not Cu. In my research, I found Ag
is more stable when it makes contacts with Si devices. I was invited to
give a talk at IBM on the metallization of advanced chips. After the talk,
I did a survey. Only 15% of the audience agreed with me and preferred
Ag. But 85% of them preferred Cu. Later, I heard that they were not in
favor of Ag because of their bad experience in Ag when they used it for
packaging application. They observed “Ag worms” where Ag would
diffuse around and form short circuit when the chip package was heated.
On the other hand, they had successfully applied Cu to fabricate metal
lines using an electro-chemical means.
15
2-5. SRC Center for Advanced Interconnect Science and Technology
At that time, a world-renowned scientist, Dr.
Shyam Murarka (see Fig. 2-6) retired from
Bell Laboratory and joined RPI in 1984 as a
faculty in the Materials Science and
Engineering Department. In 1996, he
established an SRC funded Center called
Fig. 2-6. Dr. Shyam Murarka.
“Center for Advanced Interconnect Science
and Technology, or (CAIST) at RPI where he
served as the Center Director and I as the Associate Director. A year later
(1997), he retired from RPI, and I took over his job and became the
Director. Over time, the Center involved 15 universities, 30 faculty and
40 graduate students conducting research in advanced interconnect
technology. Fig. 2-7 shows my CAIST
research review presentation at the 2002
Annual Meeting at RPI.
16
the Center activities and research
progress. Domestic companies
include Intel, IBM, AMD (Advanced
Micro Devices), TI (Texas
Instruments). Asian companies include
UMC (United Microelectronics
Corporation) in Taiwan, later TSMC in
Taiwan also joined SRC. Chartered
https://www.src.org/about/corporate-
Semiconductor Manufacturing Inc.
annual/2005.pdf
Fig. 2-8. Toh-Ming Lu received The
(now Global Foundries) in Singapore is
SRC Faculty Leadership Award at
TECHCON 2005, Portland Oregon.
also a member company. CAIST
attracted the best graduate students to do research in the country, both
domestic and international students. By the time I stepped down as the
Director of CAIST in 2005, the center had produced over 100 PhD
students. They played leadership roles in the semiconductor industry. I
received “The SRC Faculty Leadership Award” in 2005 during the annual
meeting in Portland, Oregon. See Fig. 2-8.
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2-6. The rise of semiconductor industry in Asia
Starting around 2000, semiconductor manufacturing began to move
outside the USA, in particular, to Korea and Taiwan. Japan, being very
strong in semiconductor manufacturing in the past, still played a
significant role, particularly in processing materials and lithography.
Samsung in Korea focused on memory chips while Taiwan
Semiconductor Manufacturing Company (TSMC) in Taiwan focused on
logic chips. Fig. 2-9 shows the founder of TSMC,
Morris Chang. TSMC had an interesting strategy.
They focused on manufacturing chips and no chip
design for themselves. So, there was no conflict of
Fig. 2-9. Morris
interest with the customers. Because of this strategy, Chang of TSMC.
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There had been explosive expansion of applications in semiconductors,
th
5G (the 5 generation communication network), AI (artificial intelligence),
automobile, etc. In addition
to many consumer
electronics, light emitting
diodes (LED), solar cells,
drones and satellites also rely
on semiconductor devices.
Fig. 2-10. This chart shows the explosive
There are also increasingly applications of semiconductor chips. Ref: KLA, 2023
International Semiconductor Executive Summit,
medical and biological Phoenix AZ. (https://www.ises-usa.com/)
19
Chapter 3. The Novellus connection
3-1. Novellus-Fudan Cu interconnect workshop
Novellus Systems is a major semiconductor
equipment manufacturing company who
specializes in chip fabrication tools. In 2004,
https://www.directorsandb
Novellus Systems President-CEO, Richard Hill oards.com/roster/individu
al/richard-s-hill
saw the potential business in China. He donated a
Fig. 3-1. Richard Hill,
semiconductor manufacturing equipment called CEO of Novellus Systems
20
Duquette from RPI. Lu, Ho, and Tu are
shown in Fig. 3-3. Professor Duquette is
L H T
shown in Fig. 3-4. The focus of the
workshop was on emerging Cu
technology. Duqu
Attendees included faculty and students Fig. 3-3. Partial list of speakers at the
Novellus-Fudan workshop for Cu
from Peking University, Tsinghua technology.
21
entitled: “Dielectrics and metal barriers for Cu technology” (Fig. 3-5).
22
Chapter 4. International graduate students
4-1. Entering Chinese graduate students
Over the years, I had been fortunate enough to have many international
students working with me. That included many Chinese and Indian
students. They are incredibly talented. For Indian students, I was most
impressed by those who graduated from IIT (Indian Institutes of
Technology). Here I would like to mention the unusual educational and
career paths that some of the Chinese students took. In 1978, China
resumed college entrance exams. Students who took the exams had no
formal high school education. They had to self-study the relevant subjects
before they took the exams. These students were extremely hard-working
and talented.
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4-2. Serving semiconductor industry
Here I list some former Chinese students who went to work for
semiconductor industry. Simon Yang (Fig. 4-1), CEO and founder
of Yangtze Memory Technologies Corp in Wuhan. Prior to that, he had
served as VP for Logic Development, SMIC, Shanghai and CTO of
Chartered Semiconductor (now Global foundries) in Singapore. After he
graduated in 1987, he interviewed at IBM. The technical managers were
in favor of hiring him as a technical staff. But the Human Resource
division denied his application because he was not a US citizen. He then
interviewed at Intel. Intel had a department helping international students
to apply for a permanent resident visa. Dr. Yang worked in Intel for over
10 years before he joined SMIC in Shanghai as VP for Logic Development.
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Dr. Peng Bai (Fig. 4-2) is Corporate Vice President and General Manager
of Logic Technology Development. I remember after he interviewed at
Intel, the recruiting manager called me to discuss this case. He indicated
that Dr. Bai’s thesis work was on Cu technology. But Intel’s main line
technology was Al, not Cu. I argued that in my opinion you really want to
hire a scientist with a good brain, not what he was working on when he
was a student. Dr. Bai stayed at Intel till today.
The next one is Dr. Steve Liu (Fig. 4-3). He has served as CEO of multiple
companies, including the President and CEO of Shanghai Huahong NEC
Electronics Company (now HHGRACE) from 2003 to 2009. He is
currently Managing Director of PeilinCapital in California.
25
Chapter 5. Towards the end of Si technologies
5-1. Architectures of advanced Si devices
The shrinking of Si devices has
been the main effort by
semiconductor manufacturers.
Below 16 nm technology,
Fig. 5-1. Left: Traditional field effect
Semiconductor companies had transistor (Fet). Right: 3D Finfet transistor.
https://www.quora.com/What-are-FinFETs-
gone from the planar structure to and-will-they-ever-be-able-to-replace-
MOSFETS
three-dimensional (3D) structures
to effectively reduce the footprint of devices. The 3D device is called
Finfet (fin field effect transistors). Fig. 5-1 shows the comparison between
a traditional planar field effect transistor (left) and the 3D Finfet structure
(right). In a Finfet transistor, the conducting channels are on three sides of
a fin structure with a much better control of the conduction current.
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5-2. Gate all around technology
Finfet transistors have been implemented in 7 nm, 5 nm, and 3 nm
technology nodes. For 2 nm technology node, a more complicated
structure called GAA (gate all around) structure has been used (Fig. 5-2).
GAA transistors are field-effect transistors (FET) that feature a gate on all
four sides of the channel to
overcome the physical
scaling and performance
limitations of Finfets. In
Fig. 5-2. Left, a Finfet structure. Right: A GAA (gate
this structure, the vertical all around) structure.
https://www.utmel.com/blog/categories/transistors/intr
fin structure becomes oduction-to-finfet.
27
Chapter 6. Beyond Si technology
6-1. Future possibilities. The
Si device cannot shrink
indefinitely. The diameter of a
Si atom is about 0.3 nm. One
cannot produce a Si device
with a channel less than the Si
https://hdsr.mitpress.mit.edu/pub/c
atomic size. The question everyone gmjzm3c/release/3
28
parallel. The fabrication of logic and memory devices together in a chip
poses a serious challenge.
29
of a system can be in a superposition of some sub-states. Fig. 6-2 shows
a schematic of a qubit. Consider a two-state quantum system. An arbitrary
state can be written as a superposition of two basic states |0> and |1>
states, |𝜓 >= 𝛼 |0 > +𝛽|1 > where 𝛼 and 𝛽 are arbitrary complex
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states.
Now if there is a second qubit that is coupled to the first qubit. The two
systems are “entangled”. There will be all together four possible
arrangements for the two entangled systems: |00 >, |01 >, |10 , and
|11 >. Here the first number in the | > refers to the first qubit and the
second number refers to the second qubit. It turns out that if there are N
qubit systems, there will be 2𝑁 possible arrangements or bits.
Remember that in classical computers, there are only two states, either |0>
or |1> state. If there are two such systems, there will be only two bits of
information one can record. In a quantum computer, two qubits can give
four bits of information and N qubits can give 2𝑁 bits of information.
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intuition and common sense.
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does not violate Einstein’s law that nothing can travel faster than light.
Here, there is no energy exchange during the communication between two
entangled systems. It is purely a quantum mechanical phenomenon. It
does look “weird” and “spooky”. But it is true!
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