Semiconductor technology is advancing below 50 nm critical dimensions bringing unprecedented challenges to process
engineering, control and metrology. Traditionally, interconnect metrology is put behind high-priority gate metrology;
however, considering metrology, process and yield control challenges this decision is not always justified. Optical
scatterometry is working its way to interconnect manufacturing process control, but scanning electron microscopy
(SEM) remains the number one critical dimension (CD) metrology for interconnect process engineering and optical
proximity correction (OPC) modeling. Recently, several publications have described secondary electron (SE) trapping
within narrow high-aspect ratio interconnect structures. In these papers, pre-dosing of the sample helped to extract SE
from the bottom of the hole and measure its diameter. Based on current understanding of the phenomenon, one should
expect that high-aspect ratio interconnect structures (holes and trenches) with critical dimensions below 100 nm may
show signs of SE trapping of various degree. As a result, there may be an uncontrolled effect on SE waveform and,
therefore, bias of CDSEM measurement. CD atomic force microscopy (AFM) was employed in this work as a reference
metrology for evaluation of uncertainty of trench and hole measurements by CDSEM. As the data indicates, CDSEM
bias shows a strong dependence on pitch of periodic interconnect structure starting from drawn CD of 50 nm. CDSEM
bias variation for the evaluated set of samples is about 19 nm. A typical OPC sample consists of both photoresist and
etched interlayer materials. As the AFM data for photoresist material indicates, the hole diameter changes quite
significantly with depth and the hole profile varies from one OPC structure to another. Abe et al. [1] have used a clever
way to correlate physical bottom diameter of holes with CDSEM measurements and demonstrated that for their process
and dimensions the SEM "top" diameter and physical bottom diameter correlate well. Unfortunately, this conclusion
can't be generalized and measurement uncertainty of CDSEM must be evaluated on an individual technology/process
basis. A more general approach to improve CDSEM accuracy is necessary which is based upon SI-traceable CDSEM
bias measurements, modeling and correction.
In this paper we demonstrate the process of creating a large-area, extreme field of view (XFOV) SEM image of a critical
layer of an IC product, using an array of images captured with a typical, production CD-SEM. Individual CD-SEM
images, taken side-by-side over a large area were processed to create a combined extreme field of view (XFOV) image.
All feature edges were identified across this XFOV image and the edges extracted, creating feature contours. The feature
contours were then compared to design and simulation data, and differences identified.
SEM microscopy is a primary method for CD measurements of features on sub-micron scale. The process of feature
characterization using SEM involves several steps that include image acquisition, image processing, image analysis and
data analysis. Each one of these steps carries an error margin that contributes to the overall accuracy of measurements.
While performing measurements at the nanoscale resolution the accuracy of the process becomes even more critical for
obtaining accurate measurements, and needs to be determined and understood. Using object with known dimensions
such as linewidth of an isolated polycrystalline ("poly") Si lines be useful for evaluating accuracy of the characterization
process and calibrating SEM instrument. Reference materials for such evaluation are being developed by NIST. To use
this approach successfully it is important to understand metrology issues involved in the image characterization process.
This work will review the scope of metrology issues involved in the process of linewidth measurement using SEM
imaging including image acquisition, image processing and segmentation, as well as data extraction and analysis using
image analysis methods. We will review and discuss methods for evaluating accuracy throughout characterization
process and obtaining reliable and repeatable measurements. The scope of study includes the use of two dimensional
simulation and modeling of SEM line images, methods for grayscale image processing and segmentation, algorithms for
obtaining statistically accurate linewidth measurements from the image that can be used for instrument calibration and
inter-laboratory studies and are generally applicable for obtaining CD measurements of line features.
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