KEYWORDS: 3D metrology, Sensors, 3D image processing, Atomic force microscopy, 3D vision, 3D acquisition, Extreme ultraviolet, Scanning electron microscopy, Phase measurement, Electron beams
We have studied MVM (Multi Vision Metrology) -SEM® E3630 to measure 3D shape of defects. The four detectors
(Detector A, B, C and D) are independently set up in symmetry for the primary electron beam axis. Signal processing
of four direction images enables not only 2D (width) measurement but also 3D (height) measurement. At last PMJ,
we have investigated the relation between the E3630’s signal of programmed defect on MoSi-HT and defect height
measured by AFM (Atomic Force Microscope). It was confirmed that height of integral profile by this tool is
correlated with AFM. It was tested that E3630 has capability of observing multilayer defect on EUV. We have
investigated correlation with AFM of width and depth or height of multilayer defect.
As the result of observing programmed defects, it was confirmed that measurement result by E3630 is well
correlated with AFM. And the function of 3D view image enables to show nm order defect.
KEYWORDS: Monte Carlo methods, Extreme ultraviolet, Scanning electron microscopy, Photomasks, Sensors, Metrology, Oxides, Signal detection, Multilayers, Electron beams
The required measurement precision for multilayered EUV mask metrology is set below 0.4 nm three
sigma. In addition to limited precision of CD-SEM, there are fundamental physical factors that deteriorate
the accuracy of the measurements, the most important of which is charging. It is widely believed that
EUV masks are conductive. However, experiments have revealed noticeable charging in CD-SEM
measurements of EUV masks that cannot be ignored. In this work, the results of the experiments and
simulations of the SEM signals are presented. It was shown that charging affects the metrology in a few
ways. The SEM signal shifts at each frame, changes with beam current and also depends on the wall
angle of the absorber. The results of the simulations are compared to experimental results.
KEYWORDS: Sensors, Signal detection, 3D metrology, Photomasks, Atomic force microscopy, Lithography, Scanning electron microscopy, Image sensors, Edge detection, Extreme ultraviolet
In next generation lithography (NGL) for the 22nm node and beyond, the three dimensional (3D) shape
measurements of side wall angle (SWA) and height of the photomask pattern will become critical for controlling the
exposure characteristics and wafer printability. Until today, cross-section SEM (X-SEM) and Atomic Force
Microscope (AFM) methods are used to make 3D measurements, however, these techniques require time consuming
preparation and observation.
This paper presents an innovative technology for 3D measurement using a multiple detector CDSEM and reports its
accuracy and precision.
KEYWORDS: Sensors, Signal detection, Photomasks, Algorithm development, 3D metrology, Polonium, Metrology, Scanning electron microscopy, Electron beams, Detection and tracking algorithms
A new metrology method for CD-SEM has been developed to measure the side wall angle of a pattern on photomask. The
height and edge width of pattern can be measured by the analysis of the signal intensity profile of each channel from multiple
detectors in CD-SEM.
The edge width is measured by the peak width of the signal intensity profile. But it is not possible to measure the accurate
edge width of the pattern, if the edge width is smaller than the primary electron beam diameter. Using four detectors, the
edge width can be measured by the peak width which appears on the subtracting signal profile of two detectors in opposition
to each other. Therefore, the side wall angle can be calculated if the pattern height is known.
The shadow of the side wall appears in the signal profile from the detector of the opposite side of the side wall.
Furthermore, we found that there was the proportional relation between pattern height and the shadow length of the signal on
one side.
This paper describes a method of measuring the side wall width of a pattern and experimental results of the side wall angle
measurements.
Influence of the prominent charging effect on the precision of measuring EUV mask features using CD-SEM was studied.
The dimensions of EUV mask features continuously measured by CD-SEM gradually varied because of the charging.
The charging effect on the measured CD variation mainly consists of three factors: 1) shift of the incident points of
primary electrons deflected by the surface charge, 2) distortions of the profiles of secondary electron signal intensity
caused by the deflection of the secondary electrons, 3) deviation of the maximum slope points of the secondary electron
signal intensity due to the variation of the image contrast. For those three factors described above, how the material
constant affect the CD variation measured by CD-SEM is discussed.
KEYWORDS: Sensors, Atomic force microscopy, Signal detection, Photomasks, Etching, 3D metrology, Tantalum, Critical dimension metrology, Scanning electron microscopy, Extreme ultraviolet
The Multiple Detector CD-SEM acquires the secondary electron from pattern surface at each detector. The 3D shape
and height of mask patterns are generated by adding or subtracting signal profile of each detector. In signal profile of the
differential image formed in difference between left and right detector signal, including concavo-convex information of
mask patterns. Therefore, the 3D shape of mask patterns can be obtained by integrating differential signal profile. This
time, we found that proportional relation between pattern height and shadow length on one side of pattern edge. In this
paper, we will report experimental results of pattern height measurement. The accuracy of measurement and side wall
angle dependency are studied. The proposal method is applied to OMOG masks.
KEYWORDS: Scanning electron microscopy, Monte Carlo methods, Edge detection, Detection and tracking algorithms, Image processing, Photomasks, Image filtering, Algorithm development, Printing, 3D image processing
We present a comparison of different methods to extract area information from images. Two different physical-based
algorithms were tested which determine the areas of arbitrarily shaped 3D nano-structures on wafers or photo-masks
(e.g. contact holes) using secondary electron images of scanning electron microscopy (SEM). One of these algorithms,
called NANOAREA, was developed by the PTB. The other one is the software package MaskEXPRESS, which was
developed by Toppan Printing Co., Ltd.
In addition to real SEM images we used Monte Carlo generated SEM images of contact holes of different shapes and
sizes. For this, the Monte Carlo simulation program MCSEM, developed at PTB, was applied. MCSEM simulates the
electron diffusion and secondary electron generation and transport in solid state material and provides simulated SEM
images of arbitrary 3D specimen structures.
NANOAREA uses basic image processing routines to estimate the edge position of a structure. Then, one-dimensional
profiles which intersect the structure boundary perpendicularly are extracted. A one-dimensional edge detection
algorithm determines the edge position on each profile. Finally these detected edge positions are used to calculate
the polygon area using the triangle method. NANOAREA showed a very small underestimation of the area of about
0.3 % with regard to the Monte Carlo simulations (i.e. sub-pixel deviation).
MaskEXPRESS has a similar approach, however employs a different edge detection algorithm. For quadratic contact
holes a very high correlation coefficient r larger than 0.99 of the CDs was seen with an offset of about 0.3 nm for the
two tested programs. Here the critical dimension (CD) is defined as the square root of the area. The deviations from
the mean offset were smaller than 1 nm over the whole investigated range. For analysis of arbitrarily shaped features
we used a double T-shaped structure. Also here almost perfect correlation was found (r = 0.98). The observed mean
offset in this case was also about 0.3 nm. The offsets depend on the length of the edge and can vary with the shape of
the structure, too.
Here we report the excellent correlation of the investigated algorithms and programs to determine area parameters
from SEM images. The results found are an important prerequisite for harmonized area measurement based on
independent algorithms and pave the way to a standardized approach to area determination and reporting of
photomask structures.
In order to analyze small reticle defects quantitatively, we have developed a function to measure differences in two
patterns using contour data extracted from SEM images. This function employs sub-pixel contour data extracted with high
accuracy to quantify a slight difference by ΔCD and ΔArea. We assessed the measurement uncertainty of the function with a
test mask and compared the sizes of programmed defects by each of conventional and proposed methods. We have also
investigated a correlation between measured minute defects in high MEEF (Mask Error Enhancement Factor) regions and
aerial images obtained by AIMS (Aerial Image Measurement System) tool. In this paper, we will explain the Contour
Comparison Measurement function jointly developed by Toppan and Advantest and will show its effectiveness for photomask
defect analyses.
KEYWORDS: Photomasks, Extreme ultraviolet, Scanning electron microscopy, Metrology, Pixel resolution, Time metrology, 3D metrology, Scatterometry, Electron beams, Reflectivity
The verification of not only two-dimensional feature but also three-dimensional feature, sidewall angle (SWA), has
been becoming increasingly important in NGL mask fabrication. The OMOG (Opaque MoSi on Glass) mask for ArF
immersion lithography with double patterning and the reflective type mask for EUV (Extreme Ultra- Violet) lithography
are especially in need of it.
There are several metrology tools e.g. SEM, AFM, and Scatterometry for sidewall angle (SWA) measurement. We
evaluated a new SWA measurement method using white-band width (WBW), which is equivalent to mask pattern edge
width, by CD-SEM. In general, WBW correlates with SWA. It narrows as SWA becomes steeper. However, the
correlation deteriorates when SWA is vertically near. This is due to the resolution limit of electron beam diameter used
for measurement. We analyzed the new approach to measure SWA by CD-SEM to solve this problem. And the analysis
revealed that WBW changes proportionately electron beam current value. The amount of width change depends on
SWA.
In this paper, we will describe the new SWA measurement method and its evaluation results as well as SWA
measurement results of OMOG and EUV masks.
Photomask pattern sizes are usually defined by a one-dimensional Critical Dimension (CD). As mask pattern shapes
become more complex, a single CD no longer provides sufficient information to characterize the mask feature. For
simple square contacts, an area measurement is generally accepted as a better choice for determining contact uniformity.
However, the area metric may not adequately characterize complex shapes; it does not lend itself to CD metrology and it
ignores pattern placement. This paper investigates new ways of measuring complex mask shapes with aggressive Optical
Proximity Correction (OPC). An example of more informative metric is center of gravity. This new metric will be
compared to more traditional mask characterization variables like CD mean to target, CD uniformity, and Image
Placement (IP). Wafer simulations of the mask shapes will be used to understand which mask pattern metrics are most
representative of the image transferred to wafer images. The results will be discussed in terms of their potential to
improve mask quality for 32nm technology and beyond.
EUV mask is a reflection-type-mask, of which film and structure are very different from those of existing masks (e.g.
Cr and MoSi). LWM9000 SEM of Vistec/Advantest was used for measurement of EUV masks. Two types of EUV
masks were used to investigate static and dynamic measurement precision and the impact of charge-up by e-beam
irradiation during measurement. An optional function of LWM9000 SEM was used to improve static precision.
Because the LWM9000 SEM uses ozone for in-situ cleaning of the work chamber, the interaction between the electron
beam and ozone presence was also investigated. The EUV mask was evaluated at the EUV wavelength before and after
e-beam scanning and measurements to determine any changes in reflectance.
Electron Projection Lithography (EPL) provides a fundamental advantage in resolution. In this paper, resolution improvement of EPL masks and minimum resolution in EPL exposure are addressed. In order to improve the mask resolution, we applied membranes thinner than typical thickness of 2 um to e-beam scattering layers of the EPL stencil masks. Although strength of the membrane generally deteriorates with decrease in the membrane thickness, the EPL masks having 1-um-thick scattering layers were feasibly fabricated. Reduction of the membrane thickness down to 1 um considerably improved the mask minimum feature size to resolve 120-nm holes and 80-nm lines which corresponded to 30 nm and 20 nm on wafer dimension, respectively, in the 4x demagnification EPL exposure system. The application of the 1-um-thick membrane simultaneously brought the high resolution and good pattern qualities: CD uniformity less than 10 nm in 3σ with pattern sidewall angle range of 90° ± 0.2°. We performed wafer exposure experiments in combination of the EPL exposure tool NSR-EB1A (Nikon) and the 1-um-thick membrane mask, and obtained the resolution performance of 40-nm holes on the wafer. We conclude that the application of the 1-um-thick membrane to the e-beam CD qualities. The exposure resolution of 40-nm holes on the wafer reveals the EPL exposure system to be a potential solution for contact layers in the future technology node.
The process of inspection and repair for LEEPL masks is increasingly required. A stencil mask inspection system EBScanner (Tokyo Seimitsu), using transmission electron beam, was investigated defect inspection capability on LEEPL masks. We fabricated a defect standard mask (DSM) in which programmed defects were formed, to estimate the performance of the inspection system. We performed experiments on printability of the DSM and Area MEEF (Mask Error Enhancement Factor) of LEEPL. As a result, correlation between area of pattern on mask and that on wafer is excellent, and Area MEEF is 1.19. The killer defect was defined based on the printing result on wafer. The defect size is measured by pattern shape analysis tool MaskEXPRESS (Toppan Printing). We checked the detection rate of killer defects and the number of false or real defects other than programmed defects by optimizing sensitivity of EBScanner. In case that a lot of false defect and very small defect (not crucial) are detected due to the non-uniformity of the pattern size, it takes too much time for defect review and practical classification. For reducing this work, we studied some solutions. And thus, we will discuss the analysis of EBScanner’s inspection image, including the defect classification.
We developed a pattern shape analysis tool (MaskEXPRESS) which can evaluate quantitatively photomask pattern and fabrication process by means of image processing arising from CD-SEM or UV microscope, or inspection machine. Although evaluation of complicated mask pattern has been performed qualitatively as yet, MaskEXPRESS makes it possible to evaluate it quantitatively. MaskEXPRESS can also be applied to quantitative evaluation of sensitivity of inspection machine, accuracy of EB writing, and optimization of photomask fabrication process. This paper describes the outline of MaskEXPRESS and its functions. We investigated about the precision criteria of MaskEXPRESS and found out the conditions of image processing for having accuracy equal to repeatability accuracy of measurement SEM. By changing experimentally mask fabrication conditions and analyzing the patterns, the following things became clear. Hole pattern's area increase with keeping analogous shape as etching time increases. Inner serif pattern tends to change in the direction of slant as writing dose increases. The rectangle fidelity of inner and outer serif pattern is improved according to the condition of resist process. We also present the relationship between defect size and aerial image on wafer simulated utilizing MaskEXPRESS.
It has been used to measure the maximum length of defect size for the defect decision method at the reticle inspection review. But since 0.25-0.18 micrometers node, we need to have another method to measure and judge the defect because of the complicated pattern line OPC shape and defects which could not decide to be acceptable or not for sensitive defect printability. The best way to know the effect of defects is to print on wafer or to use special review tool so called optical lithography simulation microscope like AIMS in order to judge these defects. But AIMS requires optical parameter of the wafer exposure machine. And its operation takes much time. And most of the detected defects can be judged at the photomask inspection process. We propose new judgement method for defect review precisely and easily. We have developed pattern shape analysis tool that makes defect shape of inspection review image some contact hole pattern example measured by its area and intensity values or another image acquisition system like SEM some quantitative expression. This method is useful for measuring the defect on a complicated pattern like OPC, corner rounding or edge roughness as pattern quality, or area size of a contact hole. Moreover, this method does not remain at the measurement with 2D pattern and can take the total quality of the light as the flux as well. We measured the shape of the mask pattern and the defect quantitatively using this method and evaluated print possibility about the defect print step.
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