Background: Critical design configurations, so-called hotspots, have limited lithography process margins and are particularly sensitive to mask topography effects. Unfortunately, hotspot inspection at wafer-level is a costly, timeconsuming and non-exhaustive solution. On the other hand, accurate simulation of hotspots implies a very precise representation of the mask 3-D parameters which are challenging to measure directly on a reticle. Aim: In this work, we propose two complementary methods to characterize accurately hotspots without the need for wafer data. Approach: The first approach is based on Zeiss WLCD-2G aerial image metrology tool able to measure 2-dimensional high-resolution aerial images maps of any mask pattern across different focuses. The second approach uses rigorous simulations relying on very accurate mask parameters calibrated beforehand from the complete information contained in these high-resolution aerial images delivered by WLCD Results: The calibration of the mask parameters improves the matching between simulated and WLCD aerial images by almost 20% with an error of 2% (RMS). We showed with a few examples that hotspots discovered during the wafer patterning can be detected and characterized directly at the mask-level from the measured aerial images or from accurate resist simulations. Conclusions: The good matching between the rigorous simulation and WLCD as well as their capacity to predict hotspots cross-validates both methods. The calibration of the mask parameters also indicated that to achieve an even better matching our description of the mask proximity effect has to be more elaborated.
As nodes become smaller and smaller, the OPC applied to enable these nodes becomes more and more sophisticated. This trend peaks today in curve-linear OPC approaches that are currently starting to appear on the roadmap. With this sophistication of OPC, the mask pattern complexity increases. CD-SEM based mask qualification strategies as they are used today are starting to struggle to provide a precise forecast of the printing behavior of a mask on wafer. An aerial image CD measurement performed on ZEISS Wafer-Level CD system (WLCD) is a complementary approach to mask CD-SEMs to judge the lithographical performance of the mask and its critical production features. The advantage of the aerial image is that it includes all optical effects of the mask such as OPC, SRAF, 3D mask effects, once the image is taken under scanner equivalent illumination conditions. Additionally, it reduces the feature complexity and analyzes the printing relevant CD.
The appropriate representation of the photomask in the simulation of wafer lithography processes has been shown to be of vital importance for 14-nm and below [1]. This task is difficult, since accurate optical metrology and physical metrology of the three-dimensional mask structure is not always available. OPC models for wafer patterning comprise representations of the mask, the optics, and the photoresist process. The traditional calibration of these models has involved empirical tuning of model parameters to CD-SEM data from printed photoresist patterns. Such a flow necessarily convolves the resist effects and it has been difficult to reliably obtain mask and optical parameters which are most representative of physical reality due to aliasing effects. In this work, we have undertaken to decouple the mask model from the photoresist process by use of the ZEISS Wafer-Level CD (WLCD) tool based upon aerial image metrology. By measuring the OPC test pattern mask with WLCD, the mask parameters in the OPC model can be tuned directly without interference of resist effects. This work utilized 14-nm,10-nm, and 7-nm node masks, and we demonstrate that the use of such a flow leads to the most predictive overall OPC models, and that the mask parameters resulting from this flow more closely match the expected physical values. More specifically, the mask corner rounding, sidewall angle, and bias values were tuned to the WLCD data instead of the wafer CD SEM data, and resulted in improved predictive capability of the model. Furthermore, other mask variables not traditionally tuned can be verified or tuned by matching simulation to aerial image metrology.
A calibrated Optical Proximity Correction Model (OPC) allows the accurate prediction of wafer printing results based on
the geometrically defined layout of features. Therefore the OPC Model takes physical parameter of the mask, optical
parameter of the printing system and chemical parameter of the resist into account. In order to find a good correlation
between OPC simulated data and real wafer prints, the mentioned parameter needs to be calibrated. In the past, this
calibration was done based only on the wafer CD SEM measurements. To speed up the calibration process, this paper
investigates the possibility to use the aerial image measured by a wafer level critical dimension measurement tool
(WLCD) to shorten the feedback loop and to reduce the amount of wafer prints needed for calibration.
Reticle critical dimension uniformity (CDU) is one of the major sources of wafer CD variations which include both
inter-field variations and intra-field variations. Generally, wafer critical dimension (CD) measurement sample size interfield
is much less than intra-field. Intra-field CDU correction requires time-consumption of metrology. In order to
improve wafer intra-field CDU, several methods can be applied such as intra-field dose correction to improve wafer
intra-field CDU. Corrections can be based on CD(SEM) or aerial image metrology data from the reticle. Reticle CDU
and wafer CDU maps are based on scanning electron microscope (SEM) metrology, while reticle inspection intensity
mapping (NuFLare 6000) and wafer level critical dimension (WLCD) utilize aerial images or optical techniques. Reticle
inspecton tools such as those from KLA and NuFlare, offer the ability to collect optical measurement data to produce an
optical CDU map. WLCD of Zeiss has the advantage of using the same illumination condition as the scanner to measure
the aerial images or optical CD.
In this study, the intra-field wafer CDU map correlation between SEMs and aerial images are characterized. The layout
of metrology structures is very important for the correlation between wafer intra-field CDU, measured by SEM, and the
CDU determined by aerial images. The selection of metrology structures effects on the correlation to SEM CD to wafer
is also demonstrated. Both reticle CDU, intensity CDU and WLCD are candidates for intra-field wafer CDU
characterization and the advantages and limitations of each approach are discussed.
Optical lithography stays at 193nm with a numerical aperture of 1.35 for several more years before moving to
EUV lithography. Utilization of 193nm lithography for 45nm and beyond forces the mask shop to produce
complex mask designs and tighter lithography specifications which in turn make process control more
important than ever. High yield with regards to chip production requires accurate process control.
Critical Dimension Uniformity (CDU) is one of the key parameters necessary to assure good performance and
reliable functionality of any integrated circuit. There are different contributors which impact the total wafer
CDU, mask CD uniformity, resist process, scanner and lens fingerprint, wafer topography, etc.
In this paper, the wafer level CD metrology tool WLCD of Carl Zeiss SMS is utilized for CDU measurements
in conjunction with the CDC tool from Carl Zeiss SMS which provides CD uniformity correction. The
WLCD measures CD based on proven aerial imaging technology. The CDC utilizes an ultrafast femto-second
laser to write intra-volume shading elements (Shade-In ElementsTM) inside the bulk material of the mask. By
adjusting the density of the shading elements, the light transmission through the mask is locally changed in a
manner that improves wafer CDU when the corrected mask is printed.
The objective of this study is to evaluate the usage of these two tools in a closed loop process to optimize
CDU of the mask before leaving the mask shop and to ensure improved intra-field CDU at wafer level.
Mainly we present the method of operation and results for logic pattering by using these two tools.
Optical lithography stays at 193nm with a numerical aperture of 1.35 for several more years before moving to EUV
lithography. Utilization of 193nm lithography for 32nm and beyond forces the mask maker to produce complex
mask designs and tighter lithography specifications which in turn make process control more important than ever.
High yield with regards to chip production requires accurate process control.
Critical Dimension Uniformity (CDU) is one of the key parameters necessary to assure good performance and
reliable functionality of any integrated circuit. There are different contributors which impact the total wafer CDU:
mask CD uniformity, resist process, scanner and lens fingerprint, wafer topography, etc.
In this study the newly developed wafer level CD metrology tool WLCD of Carl Zeiss SMS is utilized for CDU
measurements in conjunction with the CDC tool from Carl Zeiss SMS which provides CD uniformity correction.
The WLCD measures CD based on proven aerial imaging technology. The CDC utilizes an ultrafast femto-second
laser to write intra-volume shading elements (Shade-In ElementsTM) inside the bulk material of the mask. By
adjusting the density of the shading elements, the light transmission through the mask is locally changed in a manner
that improves wafer CDU when the corrected mask is printed.
The objective of this study is to evaluate the usage of these two tools in a closed loop process to optimize CDU of
the mask before leaving the mask shop and to ensure improved intra-field CDU at wafer level. Main focus of the
study is to investigate the correlation of applied attenuation by CDC and the resulting CD change, the impact of
CDC process on CD linearity behavior and the correlation of WLCD data and wafer data. Logic and SRAM cells
with features having designed line CD's at wafer level, ranging from 27nm to 42nm have been used for the study.
The investigation provides evidence that the applied attenuation by CDC shows a linear correlation to CD change at
wafer level measured with WLCD. Additionally, WLCD data shows that the CDC application does not impact the
CD linearity for the tested feature range. The WLCD measurement data in turn show an excellent correlation to
wafer print CD data indicating cost effective use case of closed loop WLCD/CDC application.
Using AIMSTM to qualify repairs of defects on photomasks is the industry standard. AIMSTM provides a reasonable
matching of lithographic imaging performances without the need of wafer prints. The need of utilisation of this
capability by photomask manufacturers has risen due to the increased complexity of layouts incorporating aggressive
RET and phase shift technologies as well as tighter specifications have pushed aerial image metrology to consider CD
performance results in addition to the traditional intensity verification.
The content of the paper describes the utilisation of the AIMSTM Repair Verification (RV) software for the verification
of aerial images in a mask shop production environment. The software is used to analyze images from various AIMSTM
tool generations and the two main routines, Multi Slice Analysis (MSA) and Image Compare (IC), are used to compare
defective and non-defective areas of aerial images. It is detailed how the RV software cleans "non real" errors potentially
induced by operator misjudgements, thus providing accurate and repeatable analyses all proven against the results
achieved manually.
A user friendly GUI drives the user through few simple, fast and safe operations and automatically provides summary
tables containing all the relevant results of the analysis that can be easily exported in a proper format and sent out to the
customer as a technical documentation. This results in a sensible improvement of the throughput of the printability
evaluation process in a mask manufacturing environment, providing reliable analyses at a higher productivity.
Moving forward to 32nm node and below optical lithography using 193nm is faced with complex requirements to be
solved. Mask makers are forced to address both Double Patterning Techniques and Computational Lithography
approaches such as Source Mask Optimizations and Inverse Lithography. Additionally, lithography at low k1 values
increases the challenges for mask repair as well as for repair verification and review by AIMSTM. Higher CD
repeatability, more flexibility in the illumination settings as well as significantly improved image performance must be
added when developing the next generation mask qualification equipment. This paper reports latest measurement results
verifying the appropriateness of the latest member of AIMSTM measurement tools - the AIMSTM 32-193i.
We analyze CD repeatability measurements on lines and spaces pattern. The influence of the improved optical
performance and newly introduced interferometer stage will be verified. This paper highlights both the new Double
Patterning functionality emulating double patterning processes and the influence of its critical parameters such as overlay
errors and resist impact. Beneficial advanced illumination schemes emulating scanner illumination document the
AIMSTM 32-193i to meet mask maker community's requirements for the 32nm node.
The growing complexity of reticles and continual tightening of defect specifications causes the reticle defect disposition
function to become increasingly difficult. No longer can defect specifications be distilled to a single number, nor can
past simple classification rules be employed due to the effects of MEEF on actual printing behavior. The mask maker
now requires lithography-based rules and capabilities for making these go/no-go decisions at the reticle inspection step.
We have evaluated an automated system that predicts the lithographic significance of reticle defects using PROLITHTM
technology. This printability prediction tool was evaluated and tested in a production environment using both standard
test reticles and production samples in an advanced reticle manufacturing environment. Reference measurements on
Zeiss AIMSTM systems were used to assess the accuracy of predicted results.
The application, called the Automated Mask Defect Disposition System, or AMDD, models defective and non-defective
test and reference images generated by a high-resolution inspection system. The results were calculated according to the
wafer exposure conditions given at setup such that the reticle could be judged for its 'fitness-for-use' from a lithographic
standpoint rather than from a simple physical measurement of the film materials.
We present the methods and empirical results comparing 1D and 2D Intensity Difference Metrics (IDMs) with respect to
AIMS and discuss the results of usability and productivity studies as they apply to manufacturing environments.
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