Aviram Tam

Contact hole edge roughness: circles vs. stars

The edge roughness of straight lines has received intense focus in the past, whereas the edge roughness of contact holes has been relatively unexplored. Reductions in contact hole roughness can be shown to offer improvements in electrical breakdown voltages, or potentially the opportunity for reduced cellsize. This paper introduces two CD-SEM algorithms for characterizing the amplitude and frequency of contact hole edge roughness. When combined, these two metrics proved capable of detecting differences within four wafer pairs with varying dimension and processing. Increased roughness amplitude was shown to correlate to electrical breakdown failures.

Photomask defect detection and inspection: aerial imaging and high resolution inspection strategies

Advanced photomasks exploit complex patterns that show little resemblance to the target printed wafer pattern. The main mask pattern is modified by various OPC and SRAF features while further complexity is introduced as source-mask-optimization (SMO) technologies experience early adoption at leading manufacturers. The small size and irregularity of these features challenge the mask inspection process as well as the mask manufacturing process. The two major concerns for mask inspection and qualification efficacy of advanced masks are defect detection and photomask inspectability. Enhanced defect detection is critical for the overall mask manufacturing process qualification which entails characterization of the systematic deviations of the pattern. High resolution optical conditions are the optimal solution for manufacturing process qualification as well as a source of additional information for the mask qualification. Mask inspection using high resolution conditions operates on an optical image that differs from the aerial image. The high resolution image closely represents the mask plane pattern. Aerial imaging mode inspection conditions, where the optics of the inspection tool emulates the lithography manufacturing conditions in a scanner, are the most compatible imaging solution for photomask pattern development and hence mask inspectability. This is an optimal environment for performing mask printability characterization and qualification. In this paper we will compare the roles of aerial imaging and high resolution mask inspection in the mask house.

Computational inspection applied to a mask inspection system with advanced aerial imaging capability

Traditional patterned mask inspection has been off-wavelength. For the better part of the past 25years mask inspection systems never adhered to the wavelength of the exposure tools. While in the days of contact and proximity printing this was not a major issue, with the arrival of steppers and scanners and the slow migration from 436nm, 405nm, 365nm and 248nm to ultimately 193nm, on-wavelength inspection has become a necessity. At first there was the option with defect and printline review using an at-wavelength AIMS tool [Fig 1], but now the industry has moved towards Patterned Mask Inspection to be at-wavelength too. With ever decreasing wavelength, more and more materials have become opaque, and especially the 266/257nm inspection to 193nm printing wavelength has proven to be a reliability issue. The industry took a major step forward with the adoption of at-wavelength aerial inspection, a paradigm shift in mask inspection, as it uses a hardware emulation to parallel the scanners true illumination settings [Fig 2]. The technology has found wide-spread acceptance by now, and 19xnm inspection is now the industry standard.

Aerial image based die-to-model inspections of advanced technology masks

Die-to-Model (D2M) inspection is an innovative approach to running inspection based on a mask design layout data. The D2M concept takes inspection from the traditional domain of mask pattern to the preferred domain of the wafer aerial image. To achieve this, D2M transforms the mask layout database into a resist plane aerial image, which in turn is compared to the aerial image of the mask, captured by the inspection optics. D2M detection algorithms work similarly to an Aerial D2D (die-to-die) inspection, but instead of comparing a die to another die it is compared to the aerial image model. D2M is used whenever D2D inspection is not practical (e.g., single die) or when a validation of mask conformity to design is needed, i.e., for printed pattern fidelity. D2M is of particular importance for inspection of logic single die masks, where no simplifying assumption of pattern periodicity may be done. The application can tailor the sensitivity to meet the needs at different locations, such as device area, scribe lines and periphery. In this paper we present first test results of the D2M mask inspection application at a mask shop. We describe the methodology of using D2M, and review the practical aspects of the D2M mask inspection.

Advanced edge roughness measurement application for mask metrology

With decreasing Critical Dimensions (CD), the negative influence of line edge roughness (LER) and line-width roughness (LWR) on CD uniformity and mean-to-target CD becomes more pronounced, since there is no corresponding reduction of roughness with dimension reduction. This applies to wafer metrology as well as to mask metrology. In order to better understand the types of roughness as well as the impact of the CD-SEM roughness measurement capabilities on the control of the mask process, the sensitivity and accuracy of the roughness analysis were qualified by comparing the measured mask roughness to the design for a dedicated LER test mask. This comparison is done for different LER amplitude and periodicity values and for reference structures without nominal LER using the built-in CD-SEM algorithms for LER characterization.

CD-SEM application for generic analysis of two-dimensional features on wafers and reticles

SEM Metrology becomes the standard metrology for the mask industry, as the precision and accuracy requirements tighten continuously. At the same time, analysis of general shape features becomes an important task in wafer metrology. In this paper we consider the basic requirements and suggested implementations for performing 2D metrology on reticles and wafers, [i.e. measurements of OPC (Optical Proximity Correction) structures, End of Lines, Dual Damascene and Corner Rounding]. The authors consider the following challenges related to the development of a generic algorithm for general shape 2D analysis: (1) A generic segmentation of the feature. It should be robust to noise, as well as brightness and contrast changes. (2) The complexity of two dimensional general shape features metrology. Standard CD SEM metrology is based on metrics describing simple geometric shapes such as ellipses and lines). (3) Obtaining such metrics that can be used as handles for process control (i.e. what to measure on the 2D feature). In the first part of the paper we describe a novel algorithm for segmentation and geometric analysis of general shape features based on a Smoothing Spline and the methods of differential geometry. Next, we consider the numerical methods implemented for shape analysis of noisy contours. In the second part of the paper the performance of our methods on synthetic contours of circular arc with different noise levels is demonstrated. We conclude with sample results of several suggested metrics measured on real SEM images of reticles and wafers.

Mask degradation monitoring with aerial mask inspector

As design rule continues to shrink, microlithography is becoming more challenging and the photomasks need to comply with high scanner laser energy, low CDU, and ever more aggressive RETs. This give rise to numerous challenges in the semiconductor wafer fabrication plants. Some of these challenges being contamination (mainly haze and particles), mask pattern degradation (MoSi oxidation, chrome migration, etc.) and pellicle degradation. Fabs are constantly working to establish an efficient methodology to manage these challenges mainly using mask inspection, wafer inspection, SEM review and CD SEMs. Aerial technology offers a unique opportunity to address the above mask related challenges using one tool. The Applied Materials Aera3TM system has the inherent ability to inspect for defects (haze, particles, etc.), and track mask degradation (e.g. CDU). This paper focuses on haze monitoring, which is still a significant challenge in semiconductor manufacturing, and mask degradation effects that are starting to emerge as the next challenge for high volume semiconductor manufacturers. The paper describes Aerial inspector (Aera3) early haze methodology and mask degradation tracking related to high volume manufacturing. These will be demonstrated on memory products. At the end of the paper we take a brief look on subsequent work currently conducted on the more general issue of photo mask degradation monitoring by means of an Aerial inspector.

Deployment of OASIS.MASK (P44) as direct input for mask inspection of advanced photomasks

With each new process technology node, chip designs increase in complexity and size, leading to a steady increase in data volumes. As a result, mask data prep flows require more computing resources to maintain the desired turn-around time (TAT) at a low cost. The effect is aggravated by the fact that a mask house operates a variety of equipment for mask writing, inspection and metrology - all of which, until now, require specific data formatting. An industry initiative sponsored by SEMI® has established new public formats - OASIS® (P39) for general layouts and OASIS.MASK (P44) for mask manufacturing equipment - that allow for the smallest possible representation of data for various applications. This paper will review a mask data preparation process for mask inspection based on the OASIS formats that also reads OASIS.MASK files directly in real time into the inspection tool. An implementation based on standard parallelized computer hardware will be described and characterized as demonstrating throughputs required for the 45nm and 32nm technology nodes. An inspection test case will also be reviewed.

Advanced 2D structures metrology with CD-SEM for OPC challenges

The rapid shrink of device dimensions requires not only excellent 1D CD precision, but also characterization of corner rounding and line end shape. To meet this on-going trend the industry is in a quest for higher resolution metrology tools, which in-turn drives the use of SEM metrology as more crucial. The industry challenge is to reduce corner rounding and area loss. The metrology challenge, is to be able to measure accurately and precisely these characters, in order to be able to control your process. In our study we will introduce the development of a new algorithm for general shape analysis. The purpose of this algorithm is to allow effective control of the correspondence of the feature’s shape to the design geometry. The disadvantage of the standard CD SEM metric such as contact area was discussed widely in the literature but new metrics were not discussed yet. We consider the following issues and challenges related to the development of a generic algorithm for general shape 2D analysis. First stage of this algorithm is a generic segmentation of the two dimensional features. It should be robust to noise, as well as brightness and contrast changes. Output of this phase will be the contour representing the bottom of the feature. The second stage is the obtaining of new CD metrics for these contours, especially for contours corresponding to contacts with OPC structures. We consider the corner rounding as an example of such new metric. The same techniques can be elaborated for a large range of 2D structures with different levels of complexity. The obtaining of new metrics can be useful as handles for advanced process control (i.e. what to measure on the 2D feature with complex shape such as contact with OPC structures). We consider in this paper the application of the developed metrics for reticle contact with OPC structure monitoring problem that simulates a high level of complexity.

Verification of height and sidewall angle SEM metrology accuracy using Monte Carlo simulation

Downscaling of semiconductor fabrication technology nodes brought forth a need to reassess the accuracy of 3D metrology. Accuracy is defined relative to a reference tool measurement. The authors have studied the accuracy of 3D SEM measurement results for various feature geometries and materials, matching the results to Monte Carlo simulations. Analysis of the SEM images based on an analytical model was performed. Careful analysis of the matching curves for 3D algorithm results and reference data (geometric parameters of the feature) reviled an appropriate behavior of algorithm in the vicinity of the nominal process window, and for sufficiently small feature rounding (production node). We performed matching of 3D CD SEM measurement to reference geometry data using Monte Carlo simulation. We analyzed the accuracy of measurement for a wide range of the feature geometry parameters (height, sidewall angle, top and bottom rounding). The simple physical model for corner rounding estimation is considered. We perform the model waveform analysis of the feature rounding influence on the height measurements. Serving as a process-monitoring tool, the algorithm performance was found in agreement with the required tolerance typical of the nominal process window ± 10%. Serving on extreme R&D, where rounding further away from the nominal window ± 10% is counted significant, there lie observable deviations in accuracy of height and sidewall angle measurement. These are explained through extreme corner rounding effects.