In this paper, the impact of resist on the lithographic process window is investigated. To estimate the resolution
limit of EUVL due to the limitation from resist performance, a simplified resist model, called diffused aerial image
model (DAIM), is employed. In the DAIM, the resist is characterized by the acid diffusion length, or more generally,
resist blur. Lithographic process windows with resists of various blurs are then calculated for different technology nodes.
It is concluded that the resist blur needs to be smaller than 8 nm to achieve a reasonable window for the technology node
with the minimum pitch of 32 nm. The performance of current resists can barely fulfill this requirement. Investigation of
a more refined resist model is also initiated.
In this paper, definition of line/space patterns at 44-, 32-, and 22-nm pitches using extreme-ultraviolet lithography
(EUVL) is investigated by aerial image simulation. The results indicate that extending EUVL to the 22-nm pitch requires
reducing the mask shadowing effect, which implies reducing the mask absorber thickness as well as maintaining the
6-degree angle of incidence on the mask, if the reduction ratio of the imaging system is to be kept at 4. Reduction of the
mask absorber thickness can be realized by implementing attenuated phase-shifting masks. Otherwise, all critical
patterns must be laid out in single orientation.
A programmed-defect mask consisting of both bump- and pit-type defects on the LTEM mask substrate has been
successfully fabricated. It is seen that pit-type defects are less printable because they are more smoothed out by the
employed MLM deposition process. Specifically, all bump-type defects print even at the smallest height split of 1.7 nm
whereas pit-type defects print only at the largest depth split of 5.7 nm. At this depth, the largest nonprintable 1D and 2D
defect widths are about 23 nm and 64 nm, respectively.
A brand new CD metrology technique that can address the need for accuracy, precision and speed in near future
lithography is probably one of the most challenging items. CDSEMs have served this need for a long time,
however, a change of or an addition to this traditional approach is inevitable as the increase in the need for better
precision (tight CDU budget) and speed (driven by the demand for increase in sampling) continues to drive the
need for advanced nodes.
The success of CD measurement with scatterometry remains in the capability to model the resist grating, such as,
CD and shape (side wall angle), as well as the under-lying layers (thickness and material property). Things are
relatively easier for the cases with isotropic under-lying layers (that consists of single refractive or absorption
indices). However, a real challenge to such a technique becomes evident when one or more of the under-lying
layers are anisotropic.
In this technical presentation the authors would like to evaluate such CD reconstruction technology, a new
scatterometry based platform under development at ASML, which can handle bi-refringent non-patterned layers
with uniaxial anisotropy in the underlying stack. In the RCWA code for the bi-refringent case, the elegant
formalism of the enhanced transmittance matrix can still be used. In this paper, measurement methods and data
will be discussed from several complex production stacks (layers). With inclusion of the bi-refringent modeling,
the in-plane and perpendicular n and k values can be treated as floating parameters for the bi-refringent layer, so
that very robust CD-reconstruction is achieved with low reconstruction residuals. As a function of position over
the wafer, significant variations of the perpendicular n and k values are observed, with a typical radial fingerprint
on the wafer, whereas the variations in the in-plane n and k values are seen to be considerably lower.
A new metrology technique is being evaluated to address the need for accuracy, precision, speed and sophistication in metrology in near-future lithography. Attention must be paid to these stringent requirements as the current metrology capabilities may not be sufficient to support these near future needs. Sub-nanometer requirements in accuracy and precision along with the demand for increase in sampling triggers the need for such evaluation.
This is a continuation of the work published at SPIE Asia conference, 2008. In this technical presentation the authors would like to continue on reporting the newest results from this evaluation of such technology, a new scatterometry based platform under development at ASML, which has the potential to support the future needs.
Extensive data collection and tests are ongoing for both CD and overlay. Previous data showed overlay performance on production layers [1] that meet 22 nm node requirements. The new data discussed in this presentation is from further investigation on more process robust overlay targets and smaller target designs. Initial
CD evaluation data is also discussed.
For different CD metrologies like average CD from CD SEM and optical CD (OCD) from scatterometry, CD point-to-point R2 has been well adopted as the CD correlation index. For different overlay metrologies like image-based box-in-box overlay and scatterometry-based overlay, we propose the cosine similarity as the correlation index of overlay. The cosine similarity is a measure of similarity between two vectors of n dimensions by finding the cosine of the angle
between them, often used to compare documents in text mining. It has been widely used in web and document search engines and can be used as the similarity index of overlay tool-to-tool matching and scanner tool-to-tool or day-to-day fingerprint.
In this paper, we demonstrate that the cosine similarity has a very high sensitivity to the overly tool performance. We compared the similarities of three generations (A1, A2, A3) of the overlay tools of venders A and B and found that after target re-training and TIS correction on each tool A1 similarity to A3 can be improved from 0.9837 to 0.9951. Overlay point-to-point matching with A3 vs. A1 can be reduced from 4.8 to 2.1 nm. The tool precision similarities, i.e. tool self best similarity, for A1, A2, A3 and B are 0.9986, 0.9990, 0.9995, and 0.9994 respectively. From this table, we demonstrate that we can use old-generation overlay tool with suitable hardware maintenance, to match to the latest-generation overlay tool.
Need for accuracy, precision, speed and sophistication in metrology has increased tremendously over the past few
years. Lithography performance will increasingly depend on post patterning metrology and this dependency will
be heavily accelerated by technology shrinkage. These requirements will soon become so stringent that the
current metrology capabilities may not be sufficient to support these near future needs. Accuracy and precision
requirements approaching well into sub-nanometer range while the demand for increase in sampling also
continues, triggering the need for a new technology in this area.
In this technical presentation the authors would like to evaluate such technology that has the potential to support
the future needs. Extensive data collection and tests are ongoing for both CD and overlay. Data on first order
diffraction based overlay shows unprecedented measurement precision. The levels of precision are so low that for
evaluation special methods has been developed and tested. In this paper overlay measurement method and data
will be discussed, as well as applicability for future nodes and novel lithography techniques. CD data will be
reported in the future technical publications.
Average CD of CD SEM and scatterometry CD (OCD) have been adopted for advanced CD control. The advantages and
disadvantages of these two CD metrologies have been well discussed. The target of CD uniformity (CDU) for
advanced technology has been driven to 1 nm, i.e. about three and half the size of a silicon atom, which is 0.29 nm. In
the real production environment, engineers need to face sub-nanometer (< 1 nm) CD variations and do the necessary
process corrections to meet the 1-nm CDU requirement. In other words, advanced CD process control has already been
in the world of atomic scale. It turns out that methodology to ensure the accuracy of sub-nanometer CD has become
essential for advanced CD control.
In this paper, we introduced a methodology to produce 0.25, 0.5, and 1 nm programmed pitch offsets through mask
design. These offsets are attainable with current process capability. Pitch offsets instead of line/space width offsets were
used because the pitch is relatively process insensitive. The pitch has already been widely used as a CD SEM
magnification calibration standard, e.g. Hitachi m-scale 240-nm pitch and VLSI 100-nm pitch standards. We produced
large and small pitch splits to meet different magnification linearity requirements. We also used optical CD to verify the
programmed pitch offset. Using the raw spectrum of OCD, systematic pitch signal changes in 0.25-nm steps can be
detected, ensuring that 0.25-nm pitch offset standards are meaningful. Interestingly, 0.25 nm is smaller than the 0.29-nm
Si atom.
We also used this standard wafer to do the sampling size or data quality evaluation for different CD SEM measurement
methodologies, e.g. 150K by 150K or 80K by 35K magnifications that in turn dictates the sample size. Pitch sensitivity is
strongly related to the sampling size and line-edge roughness (LER). For example, 0.25-nm pitch sensitivity needs a
larger sampling size than those of 0.5-nm and 1- nm pitch sensitivities.
By means of this standard wafer, we can easily quantify metrology quality as well as choose the right metrology and
sampling size for advanced process control.
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