Optical metrology is a science and an art. Education in the engineering disciplines concentrates on technical knowledge transfer. However, creativity and imagination are required in partnership with these technical skills to generate truly innovative results. This presentation investigates strategies and methodologies of working in which the exploration of potential solutions to optical metrology problems becomes more of a creative process than the strict application of technical know-how.
SVG Lithography (SVGL) has established and is executing a comprehensive program for the development of an advanced 157 nm Lithography Exposure System capable of processing 70 nm critical dimensions for three years now. This paper presents the approach, and details the present state of the challenges in the development of 157 nm lithography. It also describes the SVGL 157 nm program approach and provides some insight into the progress made to date addressing the challenges. Specific attention is paid to addressing 3 critical areas: Molecular contamination/purging, optical coating, and optical surfacing.
SVG Lithography (SVGL) has instigate da comprehensive program for the development of an advanced 157nm lithography exposure system of processing 70nm critical dimensions. This paper presents the need for 157nm technology to be an evolutionary approach and details the present state of the challenges in the development of 157nm lithography. It also describes the SVGL 157nm program approach and provides some insight into the progress made to date addressing the challenges.
The investigation of x-ray mask fabrication distortions was initiated in an effort to identify the fabrication parameters responsible for the final x-ray mask shape and configuration. The investigation has identified the sources of fabrication-induced distortion in x-ray mask blank manufacture. The extraction of distortions at each process step allows for mask flatness control via distortion compensation as the mask fabrication process evolves. Interferometric characterization of the final mask blank configuration guarantees the mask flatness. Mask blanks with alignment windows are mapped to determine the locations of the alignment windows relative to the membrane. An additional interferometric wedge test is performed to determine the membrane tilt magnitude and orientation relative to the backside of the mask ring. With proper selection of mask blank materials and control of membrane material deposition and bonding parameters, x-ray masks up to 100 mm in diameter have been fabricated routinely with less than 5 micrometers of bow. Fine-tuning of the x-ray mask configuration may be controlled by variations in the anodic bonding process parameters. Optimization of the anodic bonding process is currently in progress.
A high-sensitivity holographic and interferometric metrology developed at the Center for X- ray Lithography (CXrL) has been employed to investigate in-plane distortions (IPD) produced in x-ray mask materials. This metrology has been applied to characterize damage to x-ray mask materials exposed to synchrotron radiation. X-ray mask damage and accelerated mask damage studies on silicon nitride and silicon carbide were conducted on the Aladdin ES-1 and ES-2 beamline exposure stations, respectively. Accumulated in-plane distortions due to x-ray irradiation were extracted from the incremental interferometric phase maps to yield IPD vs. dose curves for silicon nitride mask blanks. Silicon carbide mask blanks were subjected to accelerated mask damage in the high flux 2 mm X 2 mm beam of the ES-2 exposure station. An accelerated damage study of silicon carbide has shown no in-plane distortion for an accumulated dose of 800 kJ/cm2 with a measurement sensitivity of less than 5 nm.
KEYWORDS: Photomasks, Finite element methods, X-ray lithography, Chemical elements, Interferometry, Temperature metrology, Kinematics, 3D modeling, X-rays, Data modeling
In general, the application of finite element modeling to x-ray lithography mask distortions has assumed ideal conditions, i.e., frictionless mounts. Under actual conditions, friction can play a part in inducing both out-of-plane (OPD) and in-plane distortions (IPD) of the x-ray mask due to mounting or environmental conditions. This paper discusses the application of nonlinear three-dimensional interface elements to simulate friction in existing finite element (FEM) models of various masks and verifies the accuracy of the modeling with interferometric studies of both OPD and IPD for different mask configurations. Once the finite element models have been verified, the friction elements are then applied to a FEM model of the ARPA-NIST Mask Standard (with a kinematic mount) to determine the effects of friction on the IPD as a function of environmental temperature and clamping force. The results of this analysis show both the importance of designing ideal mounts (i.e., frictionless) as well as maintaining a fixed environmental temperature and controlling the clamping forces during the writing and exposure of x-ray lithography masks.
X-ray lithography is a proximity printing process. After a resist-coated wafer is positioned 10-40 m behind
the x-ray mask, the mask and wafer are aligned and secured for the 'x-ray exposure. Securing the mask may create
distortions in the membrane. The lx nature of proximity printing demands that these distortions be tightly controlled.
At O.25,tm critical dimension, the distortion budget allocated to the mask is 25 nm. This corresponds to 0.7 ppm
over a field of 1" . It is thus necessary to develop a metrology tool capable of accurately and rapidly measuring
distortions induced in the mask. Interferometry, because of its non-contact nature and high sensitivity, is ideally
suited to the task. The construction of an x-ray mask begins with the deposition of a 1-2 m film onto a silicon wafer
substrate.' After carrier deposition, the mask wafer is bonded to a glass or silicon mounting ring. The mounting ring
gives the mask rigidity and provides a mechanism for mounting the mask during x-ray exposure. Mask distortions
may occur in the bonding process due to non-fiat wafers or bonding ring irregularities. The central region of mask
blank wafer is then back-etched with KOH to create an x-ray transparent membrane. The redistribution of stress in
the carrier during the membrane construction is a second source of distortion in the mask-making process. The mask
blank is subsequently patterned and metallized. Localized stresses occurring at the absorber-membrane boundaries
can lead to additional mask distortions. Several interferometric techniques can be employed to characterize the
sources of the above-mentioned x-ray mask distortions. Out-of-plane distortions (OPD) of x-ray masks have been
measured with the Michelson interferometer. In-plane distortions (IPD) in the mask have been characterized using
Moire interferometry. In Moire, diffraction gratings printed on the mask pre-exposure are examined post-exposure
in a virtual grating. Both OPD and IPD have been observed in-situ using shear interferometry.
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