Nickel (Ni) and its alloys are important multifunctional materials for the fabrication of integrated circuits, as either the absorber for the extreme ultraviolet lithography masks and/or interconnect metals at the nanometer scale. However, these applications require that Ni to be patterned controllably, selectively, and anisotropically—requirements that can only be met with a plasma based atomic layer etch (ALE) process. In this work, a plasma-thermal ALE approach is developed to pattern Ni, utilizing a nitrogen plasma to form NixN at the surface, formic acid (FA) vapor to selectively remove the NixN layer, and a low-energy Ar+ sputter process to remove carbon residue left by the FA prior to the subsequent nitridation step. This three step ALE process was shown effective to etch Ni with a rate of 1.3 ± 0.17 nm/cycle while maintaining surface smoothness.
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