III-II - ECE - VLSI Design Unit 1
III-II - ECE - VLSI Design Unit 1
COURSE MATERIAL
UNIT 1
COURSE B.TECH
DEPARTMENT ECE
SEMESTER 32
PREPARED BY
Dr. G. Sujatha
(Faculty Name/s) Professor
Version V-2
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SVCE TIRUPATI
10 ASSIGNMENTS 44
12 PART B QUESTIONS 47
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SVCE TIRUPATI
Course Objectives
1. Learn about the various processing steps involved in the fabrication of a Nmos,
Pmos AND CMOS transistors..
2. Prerequisites
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3. Syllabus
UNIT I
4. Course outcomes
2. Design digital systems using MOS circuits (Static and Switching characteristics
of inverters)
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5. CO-PO / PSO Mapping
COs/
PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PSO1 PSO2
POs
CO1
2 3
3
CO2 3 3 3
CO3
3
3
C04
3 3 3
3
6. Lesson Plan
Lecture No. Weeks Topics to be covered References
process
1.6 IDS VERSUS Vds Relationships T1, R1
Merit
2
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7. Activity Based Learning
8. Lecture Notes
1.1 INTRODUCTION
The chip design includes different types of processing steps to finish the
entire flow. For anyone, who just started his career in VLSI industry has to
understand all the steps of the VLSI design flow. Each and every step of
the VLSI design flow has a dedicated EDA tool that covers all the
aspects related to the specific task perfectly. All the EDA tools can
import and export the different file types to help making a flexible VLSI
design flow that uses multiple tools from different vendors. The VLSI
design flow is shown in the figure below.
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Fig 1.1: VLSI Design flow
1.1.1 System Specification
The first step of VLSI Design Flow is system specifications. System
specification is a high level representation of the system. The factors to be
considered in this process include performance, functionality and
interface.
1.1.1 Architectural Design
This is step where main work starts with the help of system
specification. Design engineer design the architecture according to
system specification.
1.1.3 Functional and Logic Design
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oxide or semiconductor layers that make up the components of the
Integrated circuit. Layout is designed by EDA tool such as cadence
virtuoso.
Physical design is a very complex step therefore it is divided into sub
steps such as floor planning, placement, clock tree synthesis, routing etc
and timing analysis checks are formed in each and every step during
physical design. Floor planning which is a process of placing the various
blocks and the I/O pads across the chip area based on the design
constraints. Placement of physical elements within each block and
integration of analog blocks or external IP cores is performed. When all
the elements are placed, a global and detailed routing is running to
connect all the elements together. Output of layout is GDSII file which is
given to the foundry to fabricate the chip. The layout should be done
according to foundry design rules.
1.1.6 Physical Verification and Signoff
In this step we perform physical verification checks such ass Layout Vs
schematic (LVS) and Design Rule check (DRC).DRC verifies whether the
given layout satisfies the design rules provided by the fabrication team.
DRC checks are nothing but physical checks of spacing rules between
metals, minimum width rules, via rules etc.LVS is a major check in the
physical verification stage. Layout is compared with the schematic for
verifying whether their functionally match or not. If match, then the LVS
reports clean.
1.1.7 Fabrication
After physical verification step the design is ready for fabrication. Tape
out is the final result of the design process for integrated circuits before
they are sent for manufacturing. The tape-out is specifically the point at
which the graphic for photo mask of the circuit is sent to foundry.
Fabrication process consists of several steps involving wafer growth,
epitaxial growth masking, etching, doping, deposition, and diffusion of
various materials on the wafer. During each step one mask is used.
1.1.8 Packaging and Testing
Each of the wafers contains hundreds of chips. These chips are
separated and packaged by a method called scribing and cleaving.
The chips that are failed in electrical test are discarded. Each chip is
packaged and tested to ensure that it meets all the design
specifications and functions properly.
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1.2 INTEGRATED CIRCUIT TECHNOLOGY Era:
Machining is an essential process of finishing by which work pieces are
produced to the desired dimensions and surface finish by gradually
removing the excess material from the preformed blank in the form of
chips with the help of cutting tool(s) moved past the work surface(s).
There is no doubt that our daily lives are significantly affected by
electronic engineering technology. This is true on the domestic scene, in
our professional disciplines, in the workplace, and in leisure activities.
Indeed, even at school, tomorrow’s adults are exposed to and are
coming to terms with quite sophisticated electronic devices and
systems. There is no doubt that revolutionary changes have taken place
in a relatively short time and it is also certain that even more dramatic
advances will be made in the next decade.
Electronics as we know it today is characterized by reliability, low
power dissipation, extremely low weight and volume, and low cost,
coupled with an ability to cope easily with a high degree of
sophistication and complexity. Electronics, and in particular the
integrated circuit, has made possible the design of powerful and flexible
processors which provide highly intelligent and adaptable devices for
the user. Integrated circuit memories have provided the essential
elements to complement these processors and, together with a wide
range of logic and analog integrated circuitry, they have provided the
system designer with components of considerable capability and
extensive application. Furthermore, the revolutionary advances in
technology have not yet by any means run their full course and the
potential for future developments is exciting to say the least. Up until the
1950s electronic active device technology was dominated by the
vacuum tube and, although a measure of miniaturization and circuit
integration did take place, the technology did not lend itself to
miniaturization as we have come to accept it today. Thus the vast
majority of present-day electronics is the result of the invention of the
transistor in 1947.
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Fig 1.2: Moore's first law: Transistors Integrated on a single chip
(commercial products).
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Figure 1.3: Speed/power performance of available technologies.
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Table 1.1: Microelectronics evolution
Such has been the potential of the silicon integrated circuit that
there has been an extremely rapid growth in the number of transistors
(as a measure of complexity) being integrated into circuits on a single
silicon chip. In less than three decades, this number has risen from tens
to millions as can be seen in Figure 1.1. The figure sets out what has
become known as “Moore’s first law” after predictions made by
Gordon Moore (of Intel) in the 1960s. It may be seen that his
predictions have largely come true except for an increasing
divergence between “predicted” and “actual” over the last few
years due to problems associated with the complexities involved in
designing and testing such very large circuits. Such has been the
impact of this revolutionary growth that IC technology now affects
almost every aspect of our lives. More is still to come since we have
not yet reached the limits of miniaturization and there is no doubt that
tens of millions of transistors will be readily integrated onto a single
chip in the future. This evolutionary process is reflected in Table 1.1.
Truly the 1970s, the 1980s and now the 1990s may well be described
as the integrated circuit era.
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Basic Fabrication Processes
Wafer Fabrication
The MOS fabrication process starts with a thin wafer of silicon. The raw
material used for obtaining silicon wafer is sand or silicon dioxide. Sand is a cheap
material and it is available in abundance on earth. However, it has to be purified
to a high level by reacting with carbon and then crystallized by an epitaxial
growth process. The purified silicon is held in molten state at about 1500 °C, and
a seed crystal is slowly withdrawn after bringing in contact with the molten silicon.
The atoms of the molten silicon attached to the seed cool down and take the
crystalline structure of the seed. While forming this crystalline structure, the silicon
is lightly doped by inserting controlled quantities of a suitable doping material into
the crucible. The setup is for wafer fabrication to produce nMOS devices is shown
in Fig. 1.4a. Here, boron may be used to produce p-type impurity concentration
of 1015 cm3 to 1016 per cm3. It gives resistivity in the range of 25–2 Ω cm. After the
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Withdrawal of the seed, an “ingot” of several centimeters length and about 8–10
cm diameter as shown in Fig. 1.4 b is obtained. The ingot is cut into slices of 0.3–0.4
mm thickness to obtain wafer for IC fabrication.
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Figure 1.4 c: Furnace used for oxidation
Mask Generation
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a raster scan manner, squares containing 1’s are exposed and those containing
0’s are not. Exposures are made by blanking and un-blanking the beam
controlled by the bit map. Using this technique, several different chip types can
be imprinted on the same set of masks. The main disadvantage of this approach
is that it is a sequential technique. A better alternative is to use the soft X-ray
photolithographic technique in which the entire chip can be eradicated
simultaneously. This technique also gives higher resolution.
These master plates are usually not used for mask fabrication. Working
plates made from the masters by contact printing are used for fabrication. To
reduce turn- around time, specially made master plates can be used for wafer
fabrication.
Photolithography
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To create the desired pattern, actual removal of the material is done by
the etching process. The wafer is immersed in a suitable etching solution, which
eats out the exposed material leaving the material beneath the protective
photo-resist intact. The etching solution depends on the material to be etched
out. Hydrofluoric acid (HF) is used for SiO2 and poly-silicon, whereas phosphoric
acid is used for nitride and metal.
Diffusion
After masking some parts of the silicon surface, selective diffusion can be
done in the exposed regions. There are two basic steps: pre-deposition and drive-
in. In the pre-deposition step, the wafer is heated in a furnace at 1000 °C, and
dopant atoms such as phosphorous or boron mixed with an inert gas, say
nitrogen, and are introduced into it. Diffusion of these atoms takes place onto the
surface of the silicon, forming a saturated solution of the dopant atoms and solid.
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The impurity concentration goes up with a temperature up to 1300 °C and then
drops. The depth of penetration depends on the duration for which the process is
carried out. In the drive-in step, the wafer is heated in an inert atmosphere for few
hours to distribute the atoms more uniformly and to a higher depth.
Deposition
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Poly-silicon is deposited simply by heating silane at about 1000 °C, which releases
hydrogen gas from silane and deposits silicon. To deposit silicon dioxide, a mixture of
nitrogen, silane, and oxygen is introduced at 400–450 °C. Silane reacts with oxy- gen
to produce silicon dioxide, which is deposited on the wafer.Todeposit silicon nitride
silane and ammonia are heated at about 700 °C to produce nitride andhydrogen.
Aluminium is deposited by vaporizing aluminium from a heated filament in high
vacuum.
Within the bounds of MOS technology, the possible circuit realizations may
be based on pMOS, nMOS, CMOS and now BiCMOS devices.
However, this text will deal with nMOS, then with. CMOS (which includes
pMOS transistors) and BICMOS, and finally with GaAs technology, all of which may
be classed as leading Integrated circuit technologies.
Although CMOS is the dominant technology, some of the examples used to
illustrate the design processes will be presented in nMOS form. The reasons for this
are as follows:
For nMOS technology, the design methodology and the design rules are
easily learned, thus providing a simple but excellent introduction to
structured design for VLSI.
nMOS technology and design processes provide an excellent background
for other technologies. In particular, some familiarity with nMOS allows a
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relatively easy transition to CMOS technology and design.
For GaAs technology some arrangements in relation to logic design are
similar to those employed in nMOS technology. Therefore, understanding
the basics of nMOS design will assist in the layout of GaAs circuits.
Not only is VLSI technology providing the user with a new and more
complex range of ‘off the shelf’ circuits, but VLSI design processes are
such that system designers can readily design their own special circuits of
considerable complexity. This provides a new degree of freedom for
designers and it is probable that some very significant advances will
result. Couple this with the fact that integration density is increasing
rapidly, as advances in technology shrink the feature size for circuits
integrated in silicon. Typical manufacturers’ commercial IC products have
shown this trend quite clearly as shown in Figure 1.11 and,
simultaneously, the effectiveness of the circuits produced has increased
with scaling down.
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Figure 1.2.1: Approximate minimum line width of commercial products versus
year.
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Figure 1.13: MOS transistors (VD = 0 V. Source gate and substrate to 0 V).
Consider the enhancement mode device first, shown in Figure 1.13 (a). A
polysilicon gate is deposited on a layer of insulation over the region between
source and drain. Figure 1.13(a) shows a basic enhancement mode device in
which the channel is not established and the device is in a non-conducting
condition, VD = Vs = Vgs = 0. If this gate is connected to a suitable positive voltage
with respect to the source, then the electric fluid established between the gate
and the substrate gives rise to a charge inversion region in the substrate under the
gate insulation and a conducting path or channel is formed between source and
drain.
The channel may also be established so that it is present under the
condition Vgs = 0 by implanting suitable impurities in the region between source
and drain during manufacture and prior to depositing the insulation and the
gate. This arrangement is shown in Figure 1.13(b). Under these circumstances,
source and drain are connected by a conducting channel, but the channel may
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now be closed by applying a suitable negative voltage to the gate.
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In both cases, variations and the gate voltage allow control of any current
flow between source and drain.
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available to invert the channel at the drain end so long as Vgs - Vt ≥ Vds. The
limiting condition comes when Vds = Vgs – Vt. For all voltages Vds < Vgs - Vt the
device is in the non-saturated region of operation which is the condition shown in
Figure 1.14(b).
Figure 1.3.2 : Enhancement mode transistor for particular values of Vds with
(Vgs > Vt).
Consider now what happens when Vds is increased to a level greater than
Vgs - Vt. In this case, an IR drop = Vgs - Vt takes place over less than the whole
length of the channel so that over part of the channel, near the drain, there
is insufficient electric field available to give rise to an inversion layer to create
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the channel. The channel is, therefore, ‘pinched off’ as indicated in Figure
1.14(c). Diffusion current completes the path from source to drain in this case,
causing the channel to exhibit a high resistance and behave as a constant
current source. This region, known as saturation, is characterized by almost
constant current for increase of Vds above Vds = Vgs - Vt. In all cases, the channel
will cease to exist and no current will flow when Vgs < Vt. Typically, for
enhancement mode devices, Vt = 1 volt for VDD = 5 V or, in general terms, Vt = 0.2
VDD.
n-MOS Depletion mode MOSFETs are built with P-type silicon substrates, and
P-channel versions are built on N-type substrates. In both cases they include a thin
gate oxide formed between the source and drain regions. A conductive channel
is deliberately formed below the gate oxide layer and between the source and
drain by using ion implantation. By implanting the correct ion polarity in the
channel region during fabrication determines the polarity of the threshold voltage
(i.e. -Vt for an N channel transistor, or + Vt for an P-channel transistor). The actual
concentration of ions in the substrate-to-channel region is used to adjust the
threshold voltage (Vt) to the desired value. Depletion-mode devices are a little
more difficult to manufacture and their characteristics harder to control than
enhancement types, which do not require ion implantation.
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Figure 1.3.3 : Transistor circuit symbols.
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1.4.1 nMOS Fabrication Steps
Step 2 In the SiO2 layer formed in the previous step, some regions are
defined where transistors are to be formed. This is done by the
photolithographic process discussed in the previous section with the
help of a mask (MASK 1). At the end of this step, the wafer surface is
exposed in those areas where diffusion regions along with a channel are
to be formed to create a transistor.
Step 3 A thin layer of SiO2, typically of 0.1 μm thickness, is grown all over
the entire wafer surface and on top of this poly-silicon layer is deposited.
The poly- silicon layer, of 1.5 μm thickness, which consists of heavily
doped poly-silicon is deposited using the CVD technique. In this step,
precise control of thickness, impurity con- centration, and resistivity is
necessary.
Step 4 Again by using another mask (MASK 2) and photographic
process, the poly-silicon is patterned. By this process, poly-gate structures
and interconnections by poly layers are formed.
Step 5 Then the thin oxide layer is removed to expose areas where n-
diffusions are to take place to obtain source and drain. With the poly-
silicon and underlying thin oxide layer as the protective mask, the
diffusion process is performed. It may be noted that the process is self-
aligning, i.e., source and drain are aligned automatically with respect to
the gate structure.
Step 6 A thick oxide layer is grown all over again and holes are made at
selected areas of the poly-silicon gate, drain, and source regions by
using a mask (MASK 3) and the photolithographic process.
Step 7 A metal (Aluminium) layer of 1 μm thickness is deposited on the
entire surface by the CVD process. The metal layer is then patterned
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with the help of a mask (MASK 4) and the photolithographic process.
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Necessary interconnections are provided with the help of this metal
layer.
Step 8 The entire wafer is again covered with a thick oxide layer—this is
known as over-glassing. This oxide layer acts as a protective layer to
protect different parts from the environment. Using a mask (MASK 5),
holes are made on this layer to pro- vide access to bonding pads for
taking external connections and for testing the chip.
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This diffusion should be carried out with special care since the p-well
doping concentration and depth will affect the threshold voltages as
well as the breakdown voltages of the n-transistors. To achieve low
threshold voltages (0.6 to 1.0 V) either deep-well diffusion or high-well
resistivity is required. However, deep wells require larger spacing
between the n- and p-type transistors and wires due to lateral diffusion
and therefore a larger chip area. The p-wells Act as substrates for the n-
devices within the parent n-substrate, and, the two areas are electrically
isolated. Except this in all other respects- like masking, patterning, and
diffusion-the process is similar to NMOS fabrication.
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The diagram below shows the CMOS p-well inverter showing VDD and Vss
substrate connections
1.5.2 The n-well Process : Though the p-well process is widely used in C-
MOS fabrication the n-well fabrication is also very popular because of
the lower substrate bias effects on transistor threshold voltage and also
lower parasitic capacitances associated with source and drain regions.
The typical n-well fabrication steps are shown in the diagram below.
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The first mask defines the n-well regions. This is followed by a low dose
phosphorus implant driven in by a high temperature diffusion step to
form the n-wells. The well depth is optimized to ensure against-substrate
top+ diffusion breakdown without compromising then-well to n+ mask
separation. The next steps are to define the devices and diffusion paths,
grow field oxide, deposit and pattern the poly silicon, carry out the
diffusions, make contact cuts, and finally metalize as before. Lt will be
seen that an n+ mask and its complement may be used to define the n-
and p-diffusion regions respectively. These same masks also include the
VDD and Vss contacts (respectively). It should be noted that,
alternatively, we could have used a p+ mask and its complement since
the n + and p + masks are generally complementary. The diagram
below shows the Cross-sectional view of n-well CMOS Inverter.
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1.5.3 Twin-Tub Process
Metallization
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L S I D E than
S I G Nusing
- U N I Tsilicon
-I as the substrate material, technologists have
sought to use an insulating substrate to improve process characteristics
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such as speed and latch-up susceptibility. The SOI CMOS technology
allows the creation of independent, completely isolated nMOS and
pMOS transistors virtually side-by- side on an insulating substrate. The
main advantages of this technology are the higher integration density
(because of the absence of well regions), complete avoidance of the
latch-up problem, and lower parasitic capacitances compared to the
conventional p & n-well or twin-tub CMOS processes. A cross- section of
nMOS and pMOS devices using SOI process is shown below in Figure
1.10.
The SOI CMOS process is considerably more costly than the standard p &
n-well CMOS process. Yet the improvements of device performance
and the absence of latch-up problems can justify its use, especially for
deep-sub-micron devices.
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Length of the channel (L)
Velocity (v)
Where
So, v = µ.Vds/L
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1.6.1 The Non-saturated Region:
35 | VInL Sthe
I Dnon-saturated
E S I G N - U N I T or
- I resistive region where Vds < Vgs – Vt and
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Generally , a constant β is defined as
Hence we can write another alternative form for the drain current as
Some time it is also convenient to use gate –capacitance per unit area , Cg
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1.7.2. The Saturated Region
Saturation begins when Vds = Vgs - V, since at this point the IR drop in the
channel equals the effective gate to channel voltage at the drain and
we may assume that the current remains fairly constant as Vds increases
further. Thus
Or
The expressions derived above for Ids hold for both enhancement and
depletion mode devices. Here the threshold voltage for the NMOS depletion
mode device (denoted as Vtd) is negative. MOS Transistor Threshold Voltage Vt.
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where
QB = the charge per unit area in the depletion layer below the oxide
Qss = charge density at Si: SiO2 interface
C0 =Capacitance per unit area.
Φms = work function difference between gate and Si
ΦfN = Fermi level potential between inverted surface and bulk Si
For polynomial gate and silicon substrate, the value of Φns is negative
but negligible and the magnitude and sign of Vt are thus determined by
balancing the other terms in the equation. To evaluate the Vt the other
terms are determined as below.
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Figure 1.16: Body effect – nMOS device
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1.8 MOS TRANSISTOR TRANSCONDUCTANCE GM AND OUTPUT CONDUCTANCE
GDS:
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So that
Now
In saturation
Alternatively
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1.8.1 MOS transistor figure of merit ω0
9. Practice Quiz
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4. Which provides higher integration density?
a) switch transistor logic
b) transistor buffer logic
c) transistor transistor logic
d) circuit level logic
8. p well created on
a) p substrate
b) n substrate
c) p&n substrate
d) None
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10. Which is used for the interconnection
a) boron
b) oxigen
c) silicon
d) Aluminium
10. Assignments
S.No Question BL Co
b. N well process
a. Explain IC era.
4 2 1
b. Explain thermal aspects of processing
E x pl ai n I d s Ve r s u s V d s r el a ti o n s h i p i n N o n
5 1 2
s a tu r a ti o n r e g i o n a n d S a tu r a ti o n r e g i o n .
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11. Part A- Question & Answers
Oxidation , photolithography
Metallization
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What are the steps involved in twin-tub process?
Tub Formation
3 Thin-oxide Construction 1
1
Source & Drain Implantation
Metallization
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What is Body effect?
S.No Question BL CO
Explain its operation and derive the drain to source current equation
4 in saturation and resistance region. 3 1
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13. Supportive Online Certification Courses
1. Digital circuits By Prof. Santanu Chattopdhayay, conducted by IIT Kharagpur
on NPTEL – 12 weeks
2. Digital Electronic Circuits By Prof. Goutam Saha, conducted IIT Kharagpur on
NPTEL – 12 weeks
S.No Application CO
Low Power Design for safety Critical applications: safe operation constraints vs
low-power techniques, Unsuitable low power design techniques for safety critical
applications, Low-power and safe-operating circuits
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References:
2. Wayne Wolf, “Modern VLSI Design”, Pearson Education, 3rd Edition, 1997.
3. John P. Uyemura, “Chip Design for Submicron VLSI: CMOS layout and
Simulation”, Thomson Learning.
This project aims to enhance the visual quality of images and to avoid
chances of being corrupted by impulse noise by implementing an efficient
VLSI architecture using edge preserving filter.
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