{"title":"A novel approach to tool monitoring for furnace tools with dynamic recipe management","authors":"Shiladitya Chakravorty, Chihyun Jung, Garrett Szafman, J. Rajachidambaram, Bradley Savoy, Satyajit Shinde","doi":"10.1109/ASMC.2018.8373205","DOIUrl":"https://doi.org/10.1109/ASMC.2018.8373205","url":null,"abstract":"In semiconductor manufacturing regular tool monitoring is essential for quality control. For the case of furnace tools tool monitoring is done by processing tool qualification wafers on tools followed with measurements on the wafers. Regular tool qualification methods result in either reduction in tool availability or increase in test wafer consumption. This study presents a new methodology of tool qualification using Dynamic Recipe Management which allows reduction in tool down time while keeping test wafer consumptions low.","PeriodicalId":349004,"journal":{"name":"2018 29th Annual SEMI Advanced Semiconductor Manufacturing Conference (ASMC)","volume":"19 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"121192733","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Modelling pattern dependent variations in semi-additive copper electrochemical plating: AP/DFM: Advanced patterning / design for manufacturability","authors":"C. Lang, D. Boning","doi":"10.1109/ASMC.2018.8373169","DOIUrl":"https://doi.org/10.1109/ASMC.2018.8373169","url":null,"abstract":"An empirical model is proposed for predicting layout-dependent thickness variations in the semi-additive copper electrochemical plating (ECP) process. These variations are believed to be caused by the uneven depletion of copper sulfate (CuSO4) during plating, causing low pattern density areas to plate faster than higher pattern density areas. Effective pattern density is extracted from the layout using a spatial filter, and then mapped to the growth rates using a non-linear function. Test structures are designed that represent a wide range of feature sizes and densities. After plating, these structures are profiled and used to fit the model, while similar structures are used to validate its accuracy. Comparisons between the validation predictions and the experimental results show an average Balanced Root Mean Squared Error (BRMSE) of 0.292 µm, and a corresponding R2 value of 0.90.","PeriodicalId":349004,"journal":{"name":"2018 29th Annual SEMI Advanced Semiconductor Manufacturing Conference (ASMC)","volume":"509 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"116195514","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Airborne molecular contamination: Formation, impact, measurement and removal of nitrous acid (HNO2)","authors":"J. Lobert, Reena Srivastava, F. Belanger","doi":"10.1109/ASMC.2018.8373195","DOIUrl":"https://doi.org/10.1109/ASMC.2018.8373195","url":null,"abstract":"Airborne molecular contamination (AMC) is a significant contributor to the loss of yield in semiconductor processes [1–4]. Impact of weak acids has only been considered for process technologies of 22 nm and below [5–8]. One such weak acid is nitrous acid (HNO2 or HONO), which has no demonstrated direct impact on processes or equipment, but has nevertheless been a target for removal by AMC filtration. HNO2 is commonly formed on all surfaces in all environments from NO2 gas, one of the main oxides of nitrogen formed from combustion processes and ambient air photochemistry. This study investigated the behavior of the NOX/HNOx system around typical AMC filter adsorbents. We find that NO gas passes through AMC filters unchanged, whereas NO2 is converted mostly to NO, but also to HNO2 at the low ppb level, increasing AMC load downstream of filters. Various adsorbents can capture HNO2, but filter lifetimes are short due to the release of the volatile compound over time. The recommendation is to critically evaluate the impact of HNO2 on processes and equipment and adjust AMC filtration needs accordingly.","PeriodicalId":349004,"journal":{"name":"2018 29th Annual SEMI Advanced Semiconductor Manufacturing Conference (ASMC)","volume":"74 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"124362387","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
S. Fan, S. Teehan, K. Chung, Alex Varghese, Mark Lenhardt, P. Montanini, S. Skordas, B. Haran, S. Tsai, R. Xie
{"title":"Gas cluster ion beam processing for improved self aligned contact yield at 7 nm node FinFET: MJ: MOL and junction interfaces","authors":"S. Fan, S. Teehan, K. Chung, Alex Varghese, Mark Lenhardt, P. Montanini, S. Skordas, B. Haran, S. Tsai, R. Xie","doi":"10.1109/ASMC.2018.8373209","DOIUrl":"https://doi.org/10.1109/ASMC.2018.8373209","url":null,"abstract":"Self-aligned contact (SAC) is required for 7 nm node to reduce susceptibility of contact-to-gate short failures. This requires forming a SAC cap on metal-recessed gate. The SAC cap formation is usually achieved by removing nitride on the field by planarization techniques such CMP (chemical mechanical polishing) or GCIB (gas cluster ion beam) processes. Significant gate stack height variation can be observed lot-to-lot and wafer-to-wafer due to accumulated variations from multiple steps, including several CMP steps, before the SAC cap module, especially during early research and development prior to full optimization of the steps before the SAC cap module. GCIB potentially offers a method by which the early development stage variation due to CMP steps can be reduced, allowing integration and device learning during the early stages of a program. This study shows a comparison of SAC cap formation by CMP only vs. GCIB with integrated metrology enabled location specific processing. By using GCIB with feed-forward scatterometry measurements taken from a 2D measurement pad we have been able to significantly improve both lot-to-lot and wafer-to-wafer variation on early development wafers. This has led to improvement in within wafer SAC cap thickness non-uniformity, wafer to wafer and lot to lot device yield for gate-contact over a CMP-only process flow.","PeriodicalId":349004,"journal":{"name":"2018 29th Annual SEMI Advanced Semiconductor Manufacturing Conference (ASMC)","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"131226148","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Jay K Shah, Abhinav Jain, F. Levitov, Shay Yasharzade, J. G. Sheridan, Vu Nguyen, Hoang Nguyen
{"title":"Design based automatic defect classification at advanced technology nodes: DI: Defect inspection and reduction","authors":"Jay K Shah, Abhinav Jain, F. Levitov, Shay Yasharzade, J. G. Sheridan, Vu Nguyen, Hoang Nguyen","doi":"10.1109/ASMC.2018.8373179","DOIUrl":"https://doi.org/10.1109/ASMC.2018.8373179","url":null,"abstract":"As the semiconductor industry continues to advance to smaller and smaller nodes, Defect Review Scanning Electron Microscopy (DR-SEM) and ADC (Automatic Defect Classification) face increasingly difficult challenges. The Defects of Interest (DOI) shrink as the features shrink, leading to imaging difficulty purely based on scale. Also, more complex defect analysis is required for DOI's formed during multiple patterning steps or DOI's created in previous steps. A smart approach to ADC must be adopted which allows for high quality defect classification focused on root cause analysis and yield prediction in short cycle times. In this paper, we present results from novel approach: Design Based ADC (DBA). Here, design information with current DR-SEM and ADC platforms is combined, leading to superior and robust classification.","PeriodicalId":349004,"journal":{"name":"2018 29th Annual SEMI Advanced Semiconductor Manufacturing Conference (ASMC)","volume":"9 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"115116040","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Wei-Ting Yang, J. Blue, A. Roussy, M. Reis, J. Pinaton
{"title":"Advanced run-to-run controller in semiconductor manufacturing with real-time equipment condition: APC: Advanced process control; AM: Advanced metrology","authors":"Wei-Ting Yang, J. Blue, A. Roussy, M. Reis, J. Pinaton","doi":"10.1109/ASMC.2018.8373161","DOIUrl":"https://doi.org/10.1109/ASMC.2018.8373161","url":null,"abstract":"Run-to-Run (R2R) control has become a common process regulating approach in the semiconductor industry. Conventionally, key process parameters are regulated with respect to the measured metrology data. However, wafer quality can be affected by complex factors related to equipment condition. The steady progress of information technologies enable us to collect and handle larger amounts of data, open new perspectives to explore the interactions between FDC (Fault Detection and Classification) data and product quality, i.e., wafer metrology, which should be considered simultaneously for developing improved R2R controllers. In this paper, the equipment condition is explicitly modeled and integrated into the core of a R2R controller, in order to accommodate this critical aspect of the system in deriving the control law, in order to reduce process variability in more effective way. Therefore, a new R2R control framework is proposed, which is called: Controller with Real-time Equipment Condition (CREC). The effectiveness of the new control strategy is demonstrated and validated using the case study of a Chemical-Mechanical Polishing (CMP) process, in collaboration with our industrial partner.","PeriodicalId":349004,"journal":{"name":"2018 29th Annual SEMI Advanced Semiconductor Manufacturing Conference (ASMC)","volume":"25 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"128579569","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
M. Medikonda, B. Kannan, B. Cohen, V. Chhabra, K. Onishi, G. Dilliway, A. Bello, M. Klare
{"title":"In-line XPS to quantify the changes in interfacial layers of advanced node gate stacks","authors":"M. Medikonda, B. Kannan, B. Cohen, V. Chhabra, K. Onishi, G. Dilliway, A. Bello, M. Klare","doi":"10.1109/ASMC.2018.8373182","DOIUrl":"https://doi.org/10.1109/ASMC.2018.8373182","url":null,"abstract":"In-line X-ray photoelectron spectroscopy (XPS) is a powerful tool for accurate thickness measurements on repeating ultrathin multilayer stacks using feed-forward methodology and provides composition analysis of individual elements. However, when material underneath is affected along with the surface, there is no direct method to determine loss. In this work, we present a method for quick assessment of oxidation of the various layers in a multi-layer metal gate stack as it undergoes fabrication processes post metal deposition using in-line XPS. This work also presents a study of the effect of removal processes on underlying layers of repeating multi-layer gate stacks using normalized elemental composition ratios.","PeriodicalId":349004,"journal":{"name":"2018 29th Annual SEMI Advanced Semiconductor Manufacturing Conference (ASMC)","volume":"12 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"125372085","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Metal CMP process optimization for low abrasive slurry","authors":"S. Mukherjee, Gagan Aggarwal","doi":"10.1109/ASMC.2018.8373168","DOIUrl":"https://doi.org/10.1109/ASMC.2018.8373168","url":null,"abstract":"CMP underpolish defects at back-end-of the line copper-CMP processes presents critical device reliability issues and can drive lower yields. Lower scratch defects and metal-metal isolation are the key requirements for a stable device performance. New generation low solid content slurries provide lower defects and good dishing attributes, however present planarization challenges to varying device densities. This article highlights the process optimizations that enabled the implementation of a new generation slurry on n-1 technology nodes and presents hypothesis for material removal mechanisms involving metal CMP processes. It also proposes the need to implement new material qualification BKM's across device densities and reticle design rules to enable a stable CMP planarization process.","PeriodicalId":349004,"journal":{"name":"2018 29th Annual SEMI Advanced Semiconductor Manufacturing Conference (ASMC)","volume":"15 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"122135488","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Colleen Meagher, Z. Sowinski, Chienfan Yu, Shuren Hu, K. Nummy, M. Ghosal, Ramya Viswanathan, A. Abdo, T. Wiltshire
{"title":"Patterning challenges for monolithic silicon photonics: AP/DFM: Advanced patterning / design for manufacturability","authors":"Colleen Meagher, Z. Sowinski, Chienfan Yu, Shuren Hu, K. Nummy, M. Ghosal, Ramya Viswanathan, A. Abdo, T. Wiltshire","doi":"10.1109/ASMC.2018.8373178","DOIUrl":"https://doi.org/10.1109/ASMC.2018.8373178","url":null,"abstract":"The curvilinear geometries of photonic devices are fundamentally different than the rectilinear designs of existing CMOS devices. In a monolithic integration of CMOS and photonic components, process changes to the conventional flow are required to accommodate the unique geometries of photonic devices. In this paper we discuss changes made in both fab processing and Optical Proximity Correction to improve the optical performance on a monolithic 90nm technology.","PeriodicalId":349004,"journal":{"name":"2018 29th Annual SEMI Advanced Semiconductor Manufacturing Conference (ASMC)","volume":"35 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"131371903","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pavan Samudrala, Gregory Hart, Yen-Jen Chen, Lokesh Subramany, Haiyong Gao, N. Aung, W. Chung, B. Minghetti, R. Mali, Seva Khikhlovskyi, P. Heres
{"title":"Alignment solutions on FBEOL layers using ASML scanners: AEPM: Advanced equipment processes and materials","authors":"Pavan Samudrala, Gregory Hart, Yen-Jen Chen, Lokesh Subramany, Haiyong Gao, N. Aung, W. Chung, B. Minghetti, R. Mali, Seva Khikhlovskyi, P. Heres","doi":"10.1109/ASMC.2018.8373194","DOIUrl":"https://doi.org/10.1109/ASMC.2018.8373194","url":null,"abstract":"Wafers at FBEOL layers traditionally have higher stress and larger alignment signal variability. ASML's ATHENA sensor based scanners, commonly used to expose FBEOL layers, have large spot size (∼700um). Hence ATHENA captures the signal from larger area compared to the alignment marks which are typically ∼40um wide. This results in higher noise in the alignment signal and if the surrounding areas contain periodic product structures, they interfere with the alignment signal causing either alignment rejects or in some cases-misalignment. SMASH alignment sensors with smaller spot size (∼40um) and two additional probe lasers have been used to improve alignment quality and hence reduce mark/wafer rejects. However, due to the process variability, alignment issues still persist. For example, the aluminum grain size, alignment mark trench deposition uniformity, alignment mark asymmetry and variation in stack thicknesses all contribute to the alignment signal variability even within a single wafer. Here, a solution using SMASH sensor that involves designing new alignment marks to ensure conformal coating is proposed. Also new techniques and controls during coarse wafer alignment (COWA) and fine wafer alignment (FIWA) including extra controls over wafer shape parameters, longer scan lengths on alignment marks and weighted light source between Far Infra-Red laser (FIR) and Near Infra-Red (NIR) for alignment are presented. All the above mentioned techniques, when implemented, have reduced the wafer alignment reject rate from around 36% to less than 0.1%. Future work includes mark validation based on the signal response from the various laser colors. Finally, process monitoring using alignment parameters is explored.","PeriodicalId":349004,"journal":{"name":"2018 29th Annual SEMI Advanced Semiconductor Manufacturing Conference (ASMC)","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"127054891","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}