The next milestone in the resolution of high-volume manufacturing will be achieved by High-NA EUV Lithography (HiNA EUVL) systems. In addition to the development of high-NA EUV scanners, the implementation of next generation resist materials remains a critical challenge. Thinner resists are required to accommodate DoF decrease on higher NA physics, which may lead to e-beam metrology and e-beam inspection sensitivity loss due to less electron signal and more severe stochastic failures and variabilities. Due to worse resist imaging contrast and larger pattern roughness in HiNA EUVL, accurate and high resolution CD and defect metrology as well as precise process window (PW) evaluation which considers stochastic failure rate (FR) are needed for resist screening to support the gradual reduction of resist thickness. In this paper we present a thin resist evaluation flow based on next generation e-beam metrology tool (eP6), including metrology setup and qualification and stochastic-aware process window (SAPW) analysis. We will show ADI (after development imaging) evaluation results for a contact hole array with pitch of 32nm for three CAR resist deposited thicknesses from 60nm to 30nm (note: ~40% resist thickness loss post-development). First, we will illustrate some of the metrology responses associated with thin resist and highlight the benefits of improved precision (0.7x), resolution (1.5nm) and sensitivity of next generation metrology tool. For each resist thickness, we will show CD, LCDU and defect measurements across a focus-exposure matrix. LCDU decomposition will be used to quantify SEM, mask, and stochastic contributions to the total measured LCDU. Finally, we will exhibit the SAPW result (Dose-to-Size, Depth of Focus, Exposure Latitude … etc) for the range of resist thicknesses, which can be used to optimize process centering and qualify thin resist performance for HiNA with high correlation coefficient (> 0.9) between measured FR and modeled FR.
For advanced nodes, a robust metrology is required to estimate EPE and its contributors. Especially when moving to late process development steps (Ramp-Up and High Volume Manufacturing (HVM)) where inter and intra wafer variations are small but crucial. In this study, we used 8um by 8um SEM images to assess the benefit of large Field-of-View (LFOV) metrology. The result proves the capability of LFOV metrology in capturing not only intra-wafer EPE behavior and its sensitivity to minor variations but also the minor wafer-to-wafer (W2W) variations which is not possible using a small FOV (SFOV) metrology (0.5um by 0.5um) due to larger noise level.
Improvements on on-cell overlay is necessary to suppress misalign induced defects. Precise and accurate on-cell overlay measurements are strongly demanded, however, we are facing limitations on conventional CD-SEM based on-cell overlay measurements, such as unexpected overlay bias. To mitigate drawbacks of top view based on-cell overlay measurements, we present voltage contrast based overlay measurements (VCBO) which utilize specially designed cell patterns with combinations of programmed misalignments on scribe lanes, measured by defect inspection equipment, eP5 [1]. We successfully demonstrate the first defect based overlay measurement on DRAM device and a potential of 27% in-die overlay gain is shown. Also, we display overlay process margin at about ~1000 points on wafer. As a definite standard of on-product overlay measurement, this technology will be used for advanced misreading correction (MRC). We believe that the technique would be widely used and become necessary in near future.
In this paper, budget characterization and wafer mapping of the Edge Placement Error (EPE) is studied to manage and improve pattern defects with a use case selected from SK Hynix’s most advanced DRAM 1x nm product. To quantify EPE, CD and overlay were measured at the multiple process steps and then combined for the EPE reconstruction. Massive metrology was used to capture extreme statistics and fingerprint across the wafer. An EPE budget breakdown was performed to identify main contributors and their variations. The end result shows EPEmax is mostly driven by local CD and overlay components while EPE variation is dominated by overlay and global CD components. Beyond EPE budget, a novel EPE wafer mapping methodology is introduced to visualize the temporal and spatial EPE performance which captures variation not seen from CD and overlay. This enables root-cause analysis of the pattern defects, and provides a foundation towards a better process monitoring solution. For EPE improvement, serial CD and overlay optimization simulation was performed to verify opportunities for reduction of the EPE and variation using the available ASML applications. The potential improvement for this use-case was confirmed to be 4.5% compared to baseline performance.
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