Using AIMSTM to qualify repairs of defects on photomasks is an industry standard. AIMSTM images match the
lithographic imaging performance without the need for wafer prints. Utilization of this capability by photomask
manufacturers has risen due to the increased complexity of layouts incorporating RET and phase shift technologies.
Tighter specifications by end-users have pushed AIMSTM analysis to now include CD performance results in addition to
the traditional intensity performance results.
Discussed is a new Repair Verification system for automated analysis of AIMSTM images. Newly designed user
interfaces and algorithms guide users through predefined analysis routines as to minimize errors. There are two main
routines discussed, one allowing multiple reference sites along with a test/defect site within a single image of repeating
features. The second routine compares a test/defect measurement image with a reference measurement image. Three
evaluation methods possible with the compared images are discussed in the context of providing thorough analysis
capability.
This paper highlights new functionality for AIMSTM analysis. Using structured analysis processes and innovative
analysis tools leads to a highly efficient and more reliable result reporting of repair verification analysis.
Using aerial image metrology to qualify repairs of defects on photomasks is an industry standard. Aerial image
metrology provides reasonable matching of lithographic imaging performance without the need for wafer prints.
Utilization of this capability by photomask manufacturers has risen due to the increased complexity of layouts
incorporating RET and phase shift technologies. Tighter specifications by end-users have pushed aerial image
metrology activities to now include CD performance results in addition to the traditional intensity performance results.
Discussed is the computer implemented semi-automated analysis of aerial images for repair verification activities.
Newly designed user interfaces and algorithms could guide users through predefined analysis routines as to minimize
errors. There are two main routines discussed here, one allowing multiple reference sites along with a test/defect site on
a single image of repeating features. The second routine compares a test/defect measurement image with a reference
measurement image.
This paper highlights new functionality desirable for aerial image analysis as well as describes possible ways of its
realization. Using structured analysis processes and innovative analysis tools could lead to a highly efficient and more
reliable result reporting of repair verification metrology.
In order to fully exploit the design knowledge during the operation of mask manufacturing equipment, as well as to
enable the efficient feedback of manufacturing information upstream into the design chain, close communication links
between the data processing domain and the machine are necessary.
With shrinking design rules and modeling technology required to drive simulations and corrections, the amount and
variety of measurements, for example, is steadily growing. This requires a flexible and automated setup of parameters
and location information and their communication with the machine.
The paper will describe a programming interface based on the Tcl/Tk language that contains a set of frequently
reoccurring functions for data extraction and search, site characterization, site filtering, and coordinate transfer. It
enables the free programming of the links, adapting to the flow and the machine needs. The interface lowers the effort
to connect to new tools with specific measurement capabilities, and it reduces the setup and measurement time. The
interface is capable of handling all common mask writer formats and their jobdecks, as well as OASIS and GDSII data.
The application of this interface is demonstrated for the Carl Zeiss AIMSTM system.
The photomask is a critical element in the lithographic image transfer process from the drawn layout to the final
structures on the wafer. The non-linearity of the imaging process and the related MEEF impose a tight control
requirement on the photomask critical dimensions.
Critical dimensions can be measured in aerial images with hardware emulation. This is a more recent complement to
the standard scanning electron microscope measurement of wafers and photomasks. Aerial image measurement
includes non-linear, 3-dimensional, and materials effects on imaging that cannot be observed directly by SEM
measurement of the mask. Aerial image measurement excludes the processing effects of printing and etching on the
wafer. This presents a unique contribution to the difficult process control and modeling tasks in mask making.
In the past, aerial image measurements have been used mainly to characterize the printability of mask repair sites.
Development of photomask CD characterization with the AIMSTM tool was motivated by the benefit of MEEF
sensitivity and the shorter feedback loop compared to wafer exposures.
This paper describes a new application that includes: an improved interface for the selection of meaningful locations
using the photomask and design layout data with the CalibreTM Metrology Interface, an automated recipe generation process, an automated measurement process, and automated analysis and result reporting on a Carl Zeiss AIMSTM system.
As the semiconductor industry moves toward immersion lithography using numerical apertures above 1.0 the quality of
the photomask becomes even more crucial. Photomask specifications are driven by the critical dimension (CD)
metrology within the wafer fab. Knowledge of the CD values at resist level provides a reliable mechanism for the
prediction of device performance. Ultimately, tolerances of device electrical properties drive the wafer linewidth
specifications of the lithography group. Staying within this budget is influenced mainly by the scanner settings, resist
process, and photomask quality. Tightening of photomask specifications is one mechanism for meeting the wafer CD
targets. The challenge lies in determining how photomask level metrology results influence wafer level imaging
performance. Can it be inferred that photomask level CD performance is the direct contributor to wafer level CD
performance? With respect to phase shift masks, criteria such as phase and transmission control are generally tightened
with each technology node. Are there other photomask relevant influences that effect wafer CD performance?
A comprehensive study is presented supporting the use of scanner emulation based photomask CD metrology to predict
wafer level within chip CD uniformity (CDU). Using scanner emulation with the photomask can provide more accurate
wafer level prediction because it inherently includes all contributors to image formation related to the 3D topography
such as the physical CD, phase, transmission, sidewall angle, surface roughness, and other material properties.
Emulated images from different photomask types were captured to provide CD values across chip. Emulated scanner
image measurements were completed using an AIMSTM45-193i with its hyper-NA, through-pellicle data acquisition
capability including the Global CDU MapTM software option for AIMSTM tools. The through-pellicle data acquisition
capability is an essential prerequisite for capturing final CDU data (after final clean and pellicle mounting) before the
photomask ships or for re-qualification at the wafer fab. Data was also collected on these photomasks using a
conventional CD-SEM metrology system with the pellicles removed. A comparison was then made to wafer prints
demonstrating the benefit of using scanner emulation based photomask CD metrology.
Critical dimension (CD) metrology is an important process step within the wafer fab. Knowledge of the CD values at resist level provides a reliable mechanism for the prediction of device performance. Ultimately tolerances of device electrical performance drive the wafer linewidth specifications of the lithography group. Staying within this budget is influenced mainly by the scanner settings, resist process and photomask quality. At the 65nm node the ITRS roadmap calls for sub-3nm photomask CD uniformity to support a sub-3nm wafer level CD uniformity. Meeting these targets has proven to be a challenge. What can be inferred from these specifications is that photomask level CD performance is the direct contributor to wafer level CD performance. With respect to phase shift masks, criteria such as phase and transmission control are also tightened with each technology node.
A comprehensive study is presented supporting the use of photomask aerial image emulation CD metrology to predict wafer level Across Chip Linewidth Variation (ACLV). Using the aerial image can provide more accurate wafer level prediction because it inherently includes all contributors to image formation such as the physical CD, phase, transmission, sidewall angle, and other material properties. Aerial images from different photomask types were captured to provide across chip CD values. Aerial image measurements were completed using an AIMSTMfab193i with its through-pellicle data acquisition capability including the Global CDU MapTM software option for AIMSTM tools. The through-pellicle data acquisition capability is an essential prerequisite for capturing final CD data (after final clean and pellicle mounting) before the photomask ships or for re-qualification at the wafer fab. Data was also collected on these photomasks using a conventional CD-SEM metrology system with the pellicles removed. A comparison was then made to wafer prints demonstrating the benefit of using aerial image CD metrology.
Immersion lithography offers the semiconductor industry the chance to extend the current ArF processes to smaller
nodes before switching to a shorter wavelength. The move to immersion will require increased attention to the
photomask along with new effects influencing the aerial image formation as the numerical apertures (NA) of scanners
move up to at least 0.93 and even higher. Feature sizes on the photomask become comparable or even smaller than the
wavelength and hence act more like wire grid polaris ers which lead to polarisation effects. As of today AIMSTM fab
tools are in operation worldwide. The novel AIMSTM fab 193i tool with a maximum NA of 0.93 is the latest aerial image
measurement system for ArF-lithography emulation down to the 65nm node. Common adjustments are numerical
aperture, illumination type and partial illumination coherence to match the conditions in 193nm scanners. In addition to
non-polarized illumination, the AIMSTM fab 193i allows the user to select linear x and y polarised light for different
settings and types, e.g. off-axis annular, quadrupole or dipole illumination. In this paper the polarisation effects of
different photomask features are explored by comparing measurement results using linear polarised illumination parallel
and perpendicular to line and space patterns and non-polarised illumination. Different MoSiON embedded phase shift
masks have been investigated at the highest possible NA=0.93 and for different half-pitches from 500nm to 260nm, the
latter corresponding to the 65nm node at the wafer level.
The Aerial Image Measurement System, AIMS, for 193nm lithography emulation is established as a standard for the rapid prediction of wafer printability for critical structures including dense patterns and defects or repairs on masks. The main benefit of AIMS is to save expensive image qualification consisting of test wafer exposures followed by wafer CD-SEM resist or wafer analysis. By adjustment of numerical aperture (NA), illumination type and partial coherence (σ) to match any given stepper/ scanner, AIMS predicts the printability of 193nm reticles such as binary with, or without OPC and phase shifting. A new AIMS fab 193 second generation system with a maximum NA of 0.93 is now available. Improvements in field uniformity, stability over time, measurement automation and higher throughput meet the challenging requirements of the 65nm node. A new function, “Global CD Map” can be applied to automatically measure and analyse the global CD uniformity of repeating structures across a reticle. With the options of extended depth-of-focus (EDOF) software and the upcoming linear polarisation capability in the illumination the new AIMS fab 193 second generation system is able to cover both dry and immersion requirements for NA < 1. Rigorous simulations have been performed to study the effects of polarisation for imaging by comparing the aerial image of the AIMS to the resist image of the scanner.
Repair of etched quartz defects on AAPSM products negatively affect manufacturability in the mask shop. Currently there are few solutions to repair etched quartz defects, two of these include mechanical removal or a combination of topography mapping and FIB milling of the defect. Both of the above methods involve large capital investments specifically for etched quartz repair. The method presented in this study readily repairs etched quartz without the need to purchase additional tools for AAPSM repair.
Photronics' Advanced Materials Program has developed a transparent etch stop layer (TESL) integrated into the binary blank for the purpose of building AAPSM products with a high yield component. This etch stop layer is located under a layer of sputtered SiO2 deposited to 180° for a given lithography wavelength. These blanks can be used for a variety of etched quartz applications including cPSM and CPL.
Photronics has developed software that reads in defect locations from automatic inspection tools and the jobdeck. A "repair" layer is created for the defect file and the plate is then re-exposed on the mask lithography tool. The defects are then etched away using the etch stop to control the phase of the surrounding trench.
The repair method was tested using programmed defect masks from single etched 193nm AAPSM technologies. Inspection, SEM, AIMS and profilometry results will be shown.
The extension of dry-ArF optical lithography to the 65nm node imposes many challenges to photomask makers. More than likely a flavor of Alternating Aperture Phase Shift Masks (AAPSM) will be used on the most advanced lithography layers. Although the development of AAPSM masks has validated the resolution improvement, production issues are still present. Strategies for defect inspection, disposition, and repair of quartz defects at this technology node are still in development. A comprehensive strategy for the disposition and repair of quartz defects on AAPSM photomasks will be presented. The work utilizes a 65nm node, 193nm lithography based, AAPSM programmed defect mask comprised of multiple defect types at multiple quartz depths. A strong emphasis for the work is given to 60-degree phase defects. Both a Zeiss AIMSfab 193 aerial image microscope and a FEI SNP9000 scanning probe metrology tool is used to disposition the defects. The printability of defects at various illumination settings will also be reported. Repair solutions for the defects that do “print” is also presented.
Accurate defect characterization is becoming increasingly more important with the increased implementation of AAPSM applications. Quartz bump/divot defectivity adds a third dimension to the historical definition of photomask defects that included only size and transmission. This new dimension is phase. Past studies have suggested that significant phase degradation occurs even at smaller defect sizes. This characterization is tied closely with the defect capture capability of photomask inspection. Inspection tool sensitivity to phase defects is increasingly important for at least two reasons: the danger of catastrophic defects printing on the wafer, and the newness of these types of defects to the photomask-making community at large. This experiment utilizes two distinct forms of defect characterization -- SEM sizing and surface profilometry. Programmed defect test masks were manufactured for phase shifting properties at both 248nm and 193nm exposure wavelengths. The defects were etched at multiple depths resulting in a variety of phase angle errors. This study will examine the effects of phase degradation on smaller defects along with defect capture from automatic inspection tools.
As AAPSM becomes more widely utilized, the need for defect inspection sensitivity becomes more critical. In addition, accurate defect characterization must be performed to encompass new effects caused by glass defects. Historically, defect size and position have been the two characteristics that were examined when determining inspection tool sensitivity. Because of the nature of AAPSM defects, phase is a factor that must be taken into account. This experiment utilizes two distinct forms of defect characterization -- SEM sizing, and surface profilometry. Programmed defect test masks were manufactured for phase shifting properties at both 248nm and 193nm exposure wavelengths. The defects were also etched at multiple depths resulting in a variety of phase angle errors. Utilizing the two characterization methods mentioned above, the automatic defect inspection tool's sensitivity on multiple programmed defects will be investigated.
This paper examines the effects of mask printability of various OPC defect types on a MoSi APSM mask using an MSM-100 AIMS tool operating at 248nm as a printability prediction tool. Printability analysis will be used to address differences in intensity, image capture wavelength, defocus, defect size, type, and placement on two substrate materials. Defect correlation to photomask CD error, aerial image intensity error, and MEEF on high-end KrF photomasks will also be studied.
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