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Article history: A 10 mm × 2 mm × 500 nm Al thin film was stressed with electric current at 1.5–3.0 × 105 A cm−2 for 1 h under an
Received 4 November 2016 ambient atmosphere. Ex situ variations in the sheet resistance induced by current stressing were measured with a
Received in revised form 25 May 2017 four-point probe. The critical current density for the resistance change was observed between 1.5 × 105 and 2.0 ×
Accepted 29 May 2017
105 A cm−2. The electrical resistance reached a maximum increment of 5.47% at 2.5 × 105 A cm−2. The lattice struc-
Available online 31 May 2017
ture of the Al thin film was investigated with a high resolution transmission electron microscope to determine the
Keywords:
fundamental effects of electric current stressing on the electrical property of the metal film. The high resolution lat-
Aluminum tice images incorporating a selected area fast Fourier transform indicated a large degree of lattice distortion and
Thin films high dislocation density, up to 8.60 × 1016 m−2, in the metal film after current stressing at 3.0 × 105 A cm−2.
Electrical current stressing The dislocations are believed to have been generated by the impingement of electron wind. In situ synchrotron
Electrical resistance X-ray diffraction further evidenced a high degree of lattice strain, as great as 1.1% at 3.0 × 105 A cm−2, as estimated
Dislocation density from the low angle shifts in the diffraction peaks. The generation of dislocations and the lattice strain induced by
Lattice strain current stressing were orientation-dependent, as determined by the d-spacing of the lattice orientation. The for-
mation of a high dislocation density and the subsequent buildup of lattice strain caused to an increase in electrical
resistance of the Al thin film.
© 2017 Elsevier B.V. All rights reserved.
1. Introduction formation, have been investigated at the early stage of current stressing
in view of the generation and motion of dislocations, as observed using
Electromigration in Al thin film has been shown to induce an abrupt synchrotron Laue X-ray microdiffraction [7,8]. It can be concluded ac-
increase in electrical resistance and to result in open circuit failure at the cordingly from the above mentioned studies that the generation of va-
later stage of current stressing [1]. An in situ scanning electron micro- cancies and dislocations in Al thin film at the early stage of current
scope observation evidenced the nucleation and growth of voids during stressing builds up the stress beyond the yielding stress and induces
current stressing [2]. These voids have further been shown to build up plastic deformation. This may further cause an increase in electrical re-
the tensile stress at the cathode and the stress gradient in the metal sistance. However, no study has reported direct observation of excess
film, as revealed by an in situ transmission X-ray topography [3]. The vacancies or dislocations in the lattice structure of Al thin film. There
abrupt increase in electrical resistance at the later stage of current is little understanding of variations in the lattice structure of metal
stressing is generally believed to be mainly due to the accumulation of film induced by current stressing.
the voids observed at the cathode. We recently investigated the existence of dislocations in current
It has also been shown that there is an increase in electrical resis- stressed solders using a high resolution transmission electron micro-
tance of Al thin film at the early stage of current stressing, which occurs scope (HRTEM) [9,10]. In the present study, the fundamental effects of
long before the formation of observable voids [4–6]. This early increase electric current stressing on the electrical property of Al thin film were
in electrical resistance has been ascribed to the generation of excess va- investigated. The increase in electrical resistance observed in the pres-
cancies induced by the divergence of electromigration flux [4,5]. It has ent study was correlated with the formation of a high dislocation densi-
also been inferred that the buildup of stress in metal film that exceeds ty and the subsequent buildup of lattice strain in the metal film.
the yield stress and induces plastic deformation can attribute to an
early increase in electrical resistance [6]. The plastic deformation behav- 2. Experimental details
ior of Al thin film, such as grain rotation, grain bending, and subgrain
A 10 mm × 2 mm × 500 nm sputtering deposited Al thin film was
⁎ Corresponding author. applied for the current stressing study, as shown in Fig. 1. The specimen
E-mail address: n58031015@mail.ncku.edu.tw (C.-L. Liang). was annealed at 380 °C (0.7 Tm) for 6 h in a N2 atmosphere prior to
http://dx.doi.org/10.1016/j.tsf.2017.05.044
0040-6090/© 2017 Elsevier B.V. All rights reserved.
C.-L. Liang et al. / Thin Solid Films 636 (2017) 164–170 165
Fig. 1. Schematic diagram of the sputtering deposited Al thin film stressed with electric
current.
Fig. 3. (a) Bright field TEM image of the Al thin film prior to current stressing; (b) HRTEM image of the confined region in (a) and the inset FFT diffraction pattern of the selected area; (c)
IFFT lattice image in the confined region in (b); (d) and (e), respectively, IFFT lattice images for the Al(111Þ and Al(200) orientations.
density in the Al thin film prior to current stressing is further estimated number of dislocations. The dislocations are believed to be generated
statistically as a benchmark for the specimen after current stressing, by electron wind force. The statistical analysis of the dislocation density
which will be discussed later. for the Al(111) and Al(200) orientations was further investigated and
was discussed below.
Fig. 4. (a) Bright field TEM image of the Al thin film after current stressing at 3.0 × 105 A cm−2 for 1 h; (b) HRTEM image of the confined region in (a) and the inset FFT diffraction pattern of
the selected area; (c) IFFT lattice image in the confined region in (b); (d) and (e), respectively, IFFT lattice images for the Al(111) and Al(200) orientations.
stressing, as evidenced by the bright field TEM image (submicron-scale) strain in the metals [10,14–16]. The strain measurement in these studies
(Fig. 4(a)). The HRTEM image (nano-scale), Fig. 4(b), further confirmed was conducted in the middle of the solder alloys. In addition, it has been
the void-free microstructure of the Al grain matrix. We also examined reported in both Al thin film [17] and Sn0.7Cu solder joint [18] that the
the high resolution lattice image at the grain boundary region, as strain induced by electric current stressing is dependent on the location
shown in Fig. 6. It can be seen in Fig. 6 that the grain boundary is also of the specimens, indicating the existence of a stress gradient. The stress
free of voids after electric current stressing. Based on the TEM figures, has been shown to be compressive at the anode while being tensile at
no void was formed in the Al thin film either in the matrix or in the the cathode. This indicates that the tensile stress at the cathode is
grain boundary region. It should be noted that the TEM specimens much higher than the compressive stress at the anode in Al thin film
were made from the middle of the Al thin film, which was the same lo- [17]. However, the magnitude of the compressive stress at the anode
cation as that for the four-point probe and synchrotron XRD analyses. has been found to be much higher than that of the tensile stress in the
Therefore, the increases in electrical resistance and the lattice strain ob- Sn0.7Cu solder joint [18]. The opposite results of the magnitude of stress
served in the present study are considered to be the result of dislocation in the metals might be ascribed to differences in the material character-
generation rather than the void formation mechanism in the Al thin istics, testing conditions, or specimen configurations. In the present
film. study, in situ strain evolutions in Al thin films during electric current
However, it has been reported that long-term electric current stressing were investigated with a synchrotron XRD analysis. The mea-
stressing will induce hillocks and voids at the anode and cathode, re- surements were conducted in the middle of the metal film. The d-spac-
spectively [1,2]. Therefore, dislocation densities in metal films are ex- ings of lattice planes were calculated with the Bragg equation [19]. The
pected to be location dependent. The formation of hillocks and voids lattice strain induced by electric current stressing can be estimated from
was not observed in the present study for the Al thin film stressed (dt − d0)/d0, where dt is the d-spacing of the lattice orientation after cur-
with electric current for only 1 h. It was reported that the early stage rent stressing for time t, and d0 is the original d-spacing of the lattice ori-
of electromigration induced a highly inhomogeneous distribution of entation [10]. It is noted that the lattice strain obtained through this
dislocations at the cathode and anode [7,8,13]. Dislocations were intro- method represents the relative strain value compared to that for the
duced to grains during the polygonization process as observed using original state (t = 0). In other words, the zero strain of the as-annealed
synchrotron Laue X-ray microdiffraction. However, the electric current specimen (t = 0) prior to electric current stressing is a benchmark for
stressing times for the polygonization phenomenon observed in these the evaluation of strain evolution. It is noted that there was still a resid-
studies were conducted for 14 h [7], 12 h [8], and 24 h [13], which ual strain in the matrix of the as-annealed Al thin film based on the IFFT
were much longer than 1 h of the present study. The current density lattice images (Fig. 3). The absolute values of lattice strains can be ob-
may also affect the time required for the polygonization process. There- tained using synchrotron Laue X-ray microdiffraction by indexing
fore, it is difficult to determine whether the dislocation densities at the Laue patterns and Laue spots [7,8,13]. Unfortunately, the experiment
cathode and anode are inhomogeneous at the present stage. The distri- was not accessible for the present study. Further analysis may be con-
bution of dislocation densities in Al thin film under a short period of ducted in the future to obtain the absolute values of lattice strains.
electric current stressing, such as 1 h in this case, deserves a thorough Fig. 7(a) and (b) present in situ variations (%) in the lattice strain for
investigation in future research. the Al(111) and Al(200) orientations in the range of 1.5–3.0
× 105 A cm− 2 for up to 1 h. The figure shows that the lattice strain
3.5. Variations in the lattice strain in the Al thin film induced by current rose abruptly for all current densities at the beginning of current
stressing stressing and reached an equilibrium value after a specific period of cur-
rent stressing. The time required to reach equilibrium lattice strain var-
The lattice distortion and dislocations induced by the impingement ied among current densities. The equilibrium lattice strain increased
of electron wind is believed to correspond to the lattice strain in Al with the current density and reached a maximum value as great as
thin film. In situ variations in the lattice strain induced by current 1.1% at 3.0 × 105 A cm−2. The lattice strain observed herein was induced
stressing were further investigated with a synchrotron XRD. Electric by the impingement of electron wind, and the thermal strain was in-
current stressing has been shown to induce a low angle shift in the dif- duced by Joule heating. To clarify the effect of Joule heating on the lattice
fraction peak for Sn-based solder alloys, indicating the buildup of tensile strain, a separate study as a benchmark for the thermal strain was
conducted.
Fig. 8 presents the steady-state temperatures of the Al thin film ob-
served at various current densities. The high temperature facilitates the
elimination of defects in the lattice structure and induces grain growth
in the metal film. It is evidenced from Figs. 3 and 4 that the average grain
size of the specimen increased from 84.74 nm to 99.45 nm, an incre-
ment of 16.77%, after electric current stressing at 3.0 × 105 A cm−2 for
1 h. The decrease in electrical resistance of the Al thin film at a higher
current density of 3.0 × 105 A cm−2 was thus proposed to be the result
of the grain growth mechanism induced by Joule heating. It is believed
that the generation of dislocations during electric current stressing (in-
creasing electrical resistance) and the grain growth behavior at a high
temperature (decreasing electrical resistance) are two competing
mechanisms that cause variations in the sheet resistance, as revealed
in Fig. 2.
The thermal strains observed at various current densities are pre-
sented in Fig. 9. The equivalent lattice strain induced by electron wind
force can be estimated by the difference between the total strain and
thermal strain. It can be observed that Joule heating is the dominant fac-
tor that contributes to the overall lattice strain, especially at a relatively
low current density, 1.5 × 105 A cm−2. There was no lattice strain in-
Fig. 6. HRTEM image of the Al thin film in the grain boundary region after current stressing duced as a result of electron wind force at such a low current density.
at 3.0 × 105 A cm−2 for 1 h. When the Al thin film was stressed with a higher current density, 2.0
C.-L. Liang et al. / Thin Solid Films 636 (2017) 164–170 169
Fig. 9. Overall lattice strain induced by current stressing as a combination of thermal strain
and the equivalent lattice strain induced by electron wind force.
4. Conclusions
Acknowledgements [9] Y.H. Liao, C.L. Liang, K.L. Lin, A.T. Wu, High dislocation density of tin induced by elec-
tric current, AIP Adv. 5 (2015) 127210.
[10] H.C. Huang, K.L. Lin, A.T. Wu, Disruption of crystalline structure of Sn3.5Ag induced
The authors gratefully acknowledged the financial support of the by electric current, J. Appl. Phys. 119 (2016) 115102.
Ministry of Science and Technology of the Republic of China (Taiwan) [11] A.T. Wu, A.M. Gusak, K.N. Tu, C.R. Kao, Electromigration-induced grain rotation in
anisotropic conducting beta tin, Appl. Phys. Lett. 86 (2005) 241902.
under MOST 104-2221-E-006-028-MY3. [12] H. Shen, W.X. Zhu, Y. Li, N. Tamura, K. Chen, In situ synchrotron study of
electromigration induced grain rotations in Sn solder joints, Sci. Rep. 6 (2016)
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