The influence of semiconductor manufacturing process variation on device parameter measurements for angular scatterometry was studied. Process variations, e.g, temperature and pressure variation of poly deposition, are considered to affect the optical properties of the deposition layer, and hence cause inaccurate model-based scatterometry measurements. This study investigates measurement error of device parameters if the optical properties change but the model stays for the same in angular scatterometry. A series of diffracted signatures was generated whose optical properties change slightly but keep the same structure. This work measured n (refractive index) and k (extinction index) of materials on wafer from the nominal process condition. Then, n and k are used to create a comparison library. The comparison library fixes all parameters other than varying CD (critical dimension) parameter. When poly layer n changes, the scattering signatures also change. The inaccuracy of CD measurement could be evaluated by comparing varying signatures due to optical properties change to the nominal process condition. An optimal structure design and feature region selection algorithm was developed to reduce errors introduced by these process variations to CD measurement. For angular scatterometry, the reflectance at some scan angles performs lower sensitivity to the optical parameters variation than the reflectance at other scan angles. By determining which scan angles contain less sensitivity and further optimize target design within the process variation range, the influence of process variation on device parameter measurement and the number of measurements used in the inversion process can be reduced. By using 65nm and 45nm as design rules, optimized grating structure with most sensitivity to CD measurement and the least influence on poly refractive index variation were obtained. The optimized grating structures are suitable for inline semiconductor process control of CD measurement for scatterometry.
Scatterometry has been demonstrated to be a useful measurement technique, which allows to examine a full reconstruction of the measured structure in the semiconductor process, e.g. CD, thickness, and overlay. Even though the potential of such technique has been known for many years, the challenge for extracting quickly and accurately the relevant constitutive parameters from a diffractive signature remains. In general, the device parameters are determined by finding the minimum RMSE (root mean square error) between a measured signature and theoretical signatures in the model-based library without considering the correlation among these parameters, which induces the match error problem. This study presents a novel method, applying neural network algorithm to identify the correlation between device parameters, to reduce the correlation-induced error and increase measurement precision.
Scatterometry is an optical measurement technology based on the analysis of light scattered, or diffracted, from a periodic array of features. It is not an optical imaging technique, but rather a model-based metrology that determines measurement results by comparing measured light scatter against a model of theoretical scatter 'signatures'. Conventional algorithms take the average of the difference between the experimental and modeled signatures across the full detection range, and calculate a fitting quality score parameter for the fit, eg. as a RMSE (Root Mean Square Error), MSE (Mean Square Error) or SD (Square Distance). This study reports a novel method for efficiently and accurately determining grating profiles using characteristic signature matching in a discrepancy-enhanced library generation process. Using light scattering theory, such as rigorous coupled wave theory, a series of scattering signatures vs. scattering angles or wavelengths are generated based on the designed grating parameters, eg. CD (Critical Dimension), thickness and Line:Space ratio. This method selects characteristic portions of the signatures wherever their measurement sensitivity exceeds the preset criteria and reforms a characteristic signature library for quick and accurate matching. This method does not need to modify existing measurement hardware or the grating target. It saves a great percentage of storage memory in the computer system, and also increases the measurement sensitivity.
As overlay tolerances of microlithographic technology become increasingly severe, conventional bright-field metrology systems are limited by image resolution and precision. Scatterometer (angular scatterometer or spectroscopic reflectometer, for example) has the advantages of good repeatability and reproducibility, and is proposed as an alternative solution for overlay metrology. Previous studies have applied a spectroscopic reflectometer, which is as function of incident wavelength, to overlay measurement. This work investigated overlay measurement by using an angular scatterometer, which is as function of incident angle. A focused laser spot was incident on linear grating, an overlay target. An angular signature, a 0th-order reflective light beam, scattered from linear grating was measured when the incident and reflective angles were changed simultaneously. The overlay target consists of two linear gratings located on two different layers of a stacked structure, and the overlay error is the misalignment between these two different layers. The measured results using angular scatterometer (also known as the diffraction-based method) are compared with using the bright-field microscope (also known as the image-based method), which use a bar-in-bar target as an overlay target. Statistical data sets demonstrate that angular sctterometer has nearly one order better of repeatability and tool induced shift than conventional bright-field microscope. Additionally, a series of different parameters of overlay targets, such as different pitches, line-to-space ratios, and stacked structures is designed and manufactured. The sensitivity of overlay measurement of various linear grating targets is also measured and discussed.
We report a study of the effect of target size on CD measurement by angular scatterometry in two ways. One is reducing the spot size (say to 40 mm) to permit the use of a smaller target; another is to overfill the target. Starting with standard grating targets of 80 x 80 mm size, with fixed CD 400 nm and LS (Linewidth to Spacing) ratio 1:1, test gratings have been designed with X and Y dimensions varied from 80 to 10 mm in 10 mm intervals. We show how the scattering signatures are influenced by the varying target sizes and spot sizes especially when the target grating is overfilled. The errors in CD measurements caused by the target and spot size variations are also quantified. Working with an overfilled small grating target and filtering out the specular noise offers a promising way to present the scattering signal from diffraction. An empirical model to predict the scattering signatures as a function of target size is under development.
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