On-product overlay (OPO) control in the DRAM process has become a critical component from node to node to produce high device yield. To meet OPO node goals, Non-Zero Offset (NZO) and its stability across lots must be monitored and controlled. NZO is the bias between overlay (OVL) on-target measurement at After Development Inspection (ADI) vs. on-device measurement at After Etching Inspection (AEI). In this paper, we will present Imaging-Based Overlay (IBO) metrology data at ADI of two different marks, segmented AIM® with design rule patterns and robust AIM (rAIM®) with Moiré effect with a small pitch. NZO analysis will be presented for each target type including basic performance.
Background: Process window metrology is used in manufacturing to determine best dose and focus for the scanner, but current metrology uses defect inspection to determine best focus and thus is expensive and time consuming. Aim: Ideally, an alternate stochastics metric (such as linewidth roughness for line/space patterns) could be used as a substitute for defectivity measurements, saving time and money. Approach: Here, the Probabilistic Process Window (PPW) is evaluated as an improved alternative to the plan of record approach, where only CD-SEM images are collected and evaluated. Results: The PPW was found to provide results that matched to the plan of record approach, but with increased rigor and improved precision. Conclusions: As a result, critical layers on future DRAM manufacturing nodes will use the PPW for best dose/focus scanner control.
Semiconductor layer-to-layer overlay in manufacturing significantly impacts product quality and yield performance. Good control of device shifting also influences the spatial scale down for the nanoelectronics of memory applications. Advanced node DRAM semiconductor manufacturing requires a tighter in-die overlay budget. Typically, the inline overlay is measured by using a designed target in the scribe line. However, the difference between the metrology target and in-die device structure can lead to errors that can impact product quality and yield. This is especially true for complex structures such as the DRAM storage hole to landing pad overlay that cannot be well fabricated in the small target area. To meet the required tighter overlay control budget, the ability to measure in-die is essential. In this work, we introduce and demonstrate the line scan self-calibration solution for accurate and robust in-die overlay measurement of the storage node layer to the landing pad layer. Real spectra are collected by SpectraShape 11k dimensional metrology system where overlay splits are trained against the intended overlay and the SpectraShape 11k in-device overlay results are qualified by Set (designed overlay value from lithography), Get (overlay value measured by metrology tool) and TEM. Moreover, theoretical and experimental data show that the SpectraShape 11k Mueller elements are sensitive to tiny changes in the overlay parameters, which can enable robust, inline, high throughput overlay metrology. We demonstrate that the SpectraShape 11k successfully measures the in-die overlay of the complex storage hole to the landing pad structure with good accuracy and high throughput thereby contributing to improved process control and yield improvement.
KEYWORDS: Defect detection, Inspection, Transmission electron microscopy, Signal detection, Sensors, Semiconducting wafers, Scanning electron microscopy, Defect inspection, Data storage
A high-throughput e-beam monitoring strategy was developed for capturing advanced DRAM storage node (SN) defects after etching process, when high-aspect-ratio (HAR) structure is involved. With this novel approach, two types of defects, SN-bowing-short and SN-open, were captured with solid signatures. In this study, two wafers with the same structure at different technology nodes,1A and 1B, were used. To enhance the defects signal, back scattered electron (BSE) mode was used to enhance the material contrast for the bottom of HAR holes. With improved BSE image quality, SN-bowing short type was caught using defect detection based on traditional array mode detection. SN-open, however, is more challenging because of its smaller dimension and HAR, resulting in an extremely narrow detection window of image gray level difference between normal storage node hole and the defective one. In order to capture this type of defect, an die-to-database (D2DB) comparison system for e-Beam inspection was applied to address this critical defect and its wafer signature was revealed with extremely high throughput and sensitivity.
When a novel dry-etch tool was introduced for the shallow trench isolation (STI) process, it resulted in poorer overlay performance downstream. The patterned wafer geometry (PWG™) tool was utilized to investigate the observed difference in results between the new tool and the POR tool. By using metrics representing process-induced local shape and/or stress, a post-STI oxide fill rapid thermal process (RTP) was identified as the process step where the difference between the dry-etch tools was magnified. An experiment based on RTP temperature and ramp rate was conducted and the effect was evaluated using both GEN4–a predicted shape overlay metric derived from PWG shape measurement–and overlay measurements. Both GEN4 and overlay results indicated that high RTP temperature and low ramp rate could compensate for the process effects introduced by the new etch tool. The strong correlation between GEN4 and overlay also suggested that GEN4 may be a suitable upstream predictor of process-induced overlay excursion in such a case.
Advanced DRAM technology relies heavily on 193nm immersion lithography. Negative tone develop (NTD) layers are becoming increasingly important particularly in nodes below 20nm. NTD is particularly useful for patterning holes on the wafer. Cut layers for multi-patterning (MP) applications and bit line contact structures are common uses of NTD in DRAM. Patterning these structures pose lithographic challenges around process window (PW), layer-to-layer overlay, and critical dimension (CD) control. The mask plays a critical role in optimizing all of these attributes. In this paper, we explore multiple mask enhancements to optimize wafer performance for NTD contacts. These include mask process and mask blank conditions, as well as a data enhancement technique generally known as mask process correction (MPC). Specifically, we implement a litho-aware MPC Application (LAMA) to optimize mask pattern fidelity. Finally, we harmonize these mask enhancements with optimizations to wafer exposure conditions and optical proximity correction (OPC) to demonstrate capability improvement in NTD contact lithography.
In leading edge lithography, overlay is usually controlled by feedback based on measurements on overlay targets, which are located between the dies. These measurements are done directly after developing the wafer. However, it is well-known that the measurement on the overlay marks does not always represent the actual device overlay correctly. This can be due to different factors, including mask writing errors, target-to-device differences and non-litho processing effects, for instance by the etch process.1
In order to verify these differences, overlay measurements are regularly done after the final etch process. These post-etch overlay measurements can be performed by using the same overlay targets used in post-litho overlay measurement or other targets. Alternatively, they can be in-device measurements using electron beam measurement tools (for instance CD-SEM). The difference is calculated between the standard post-litho measurement and the post-etch measurement. The calculation result is known as litho-etch overlay bias.
This study focuses on the feasibility of post-etch overlay measurement run-to-run (R2R) feedback instead of post-lithography R2R feedback correction. It is known that the post-litho processes have strong non-linear influences on the in-device overlay signature and, hence, on the final overlay budget. A post-etch based R2R correction is able to mitigate such influences.2
This paper addresses several questions and challenges related to post-etch overlay measurement with respect to R2R feedback control. The behavior of the overlay targets in the scribe-line is compared to the overlay behavior of device structures. The influence of different measurement methodologies (optical image-based overlay vs. electron microscope overlay measurement) was evaluated. Scribe-line standard overlay targets will be measured with electron microscope measurement. In addition, the influence of the intra-field location of the targets on device-to-target shifts was evaluated.
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