BackgroundThe upcoming introduction of high-numerical aperture extreme ultraviolet (EUV) lithography is accompanied by ongoing activities to mitigate the imaging issues combined with the 3D photomask absorber. In addition to suitable exposure and patterning techniques, the absorber material has a large impact on image contrast and the usable depth of focus.AimThe study of solutions to the imaging downsides combined with the EUV reflective mask typically is based on rigorous imaging simulations. We show that aerial image metrology using Aerial Image Measurement System (AIMS)® EUV is a supplementary way to verify the impact of mask 3D effects in lithography.ApproachAn AIMS® EUV study of the impact of mask 3D effects on the through-focus image formation in a three-beam interference regime is presented.ResultsExperiments on a 20-nm vertical equal lines and spaces clip using dedicated monopole illumination demonstrate a prominent, focus-dependent line-shape behavior for each of the pole positions. Applying an analytical model for three-beam-imaging in the presence of defocus and mask 3D effects, we obtain excellent agreement between measurements and theory that allows us to derive the mutual phase shifts of the single interference cross-terms involved.ConclusionsUsing AIMS® EUV, an evaluation of the imaging impact of various absorber materials can be done experimentally without relying on wafer exposures.
KEYWORDS: 3D mask effects, Light sources and illumination, Extreme ultraviolet, Diffraction, 3D image processing, 3D modeling, Phase shifts, Simulations, 3D metrology, Extreme ultraviolet lithography
The upcoming introduction of High-NA EUV lithography in chip manufacturing is accompanied by still ongoing activities to mitigate the imaging issues combined with the 3D photomask absorber. Besides suitable exposure and patterning techniques, the mask absorber material has large impact on image contrast and the usable depth of focus. In recent years, 3D mask effects in EUV lithography have widely been investigated, and alternative absorber stacks which enable improved contrast and focus control have been proposed. The study of solutions to the challenges combined with the EUV reflective mask typically is based on rigorous imaging simulations. However, aerial image metrology can be a supplementary way to verify the impact of mask 3D effects on lithography. For this purpose, the AIMS® EUV actinic mask measurement represents a highly precise way to qualify the High-NA mask printing performance under scanner-equivalent optical column conditions. In this paper, we present an AIMS® EUV study of the impact of mask 3D effects on the through-focus image formation in a three-beam interference regime. Our experiments on a dense vertical 20nm lines and spaces clip using dedicated monopole illumination demonstrate a prominent, focus-dependent line shape deformation for each of the single pole positions. For the center monopole setting, frequency doubling of the aerial image is observed for one particular focus value. To describe the line shapes recorded, we applied an analytical model for three-beam-imaging in the presence of defocus and mask 3D effects. We obtained an excellent agreement between measurements and calculated data that allows us to derive the mutual phase-shifts of the single interference cross-terms involved. We conclude that the aerial image behavior as observed can be traced back to a coupling of the defocus aberration and mask 3D driven effects.
In parallel to the development of EUV lithography equipment and processes towards High-NA there is a still growing interest to study and understand the role of 3D mask absorber driven effects on imaging. Alongside with appropriate exposure and patterning techniques, the choice of a suitable mask absorber material has large impact on the process window optimization. The development of solutions to the challenges combined with the EUV reflective mask typically is based on rigorous imaging simulations, but aerial image metrology can be a supplementary way to verify the role of mask 3D effects on lithography. For that purpose, the ZEISS AIMS EUV actinic mask measurement represents a unique and variously usable way for the qualification of the current as well as the next generation High-NA mask printing performance under scanner-equivalent optical column conditions. In this paper, we show results of AIMS® EUV measurements at Ta-based absorber masks where we identify a significant impact of mask 3D driven phase shifts on the aerial images. For a standard High-NA dipole setting, the intensity profiles of a dense 18 nm vertical lines and spaces structure show an initially unexpected line splitting through focus that can be reproduced by rigorous imaging simulations. In contrast, no splitting is found if the experiment is described within a 2D model. A follow-up experiment on a similar dense vertical 20 nm lines and spaces clip with dedicated monopole illumination demonstrates a prominent asymmetric line splitting for each of the single pole positions, again in accordance with simulation. For a center monopole setting we see a frequency doubling of the aerial image for one particular focus position. To describe the aerial image behavior, we applied an analytical model for three-beam-imaging in the presence of defocus and mask 3D effects. Consequently, the observed through-focus behavior can be explained by various phase shifts to the three-beam imaging cross-terms involved.
High-NA EUV lithography is being prepared for the next stage of volume production of state-of-the-art integrated devices. First wafer exposures on ASML’s EXE5000 are expected early in 2024. Beyond assessment of the benefit of high-NA by simulation, ZEISS AIMS EUV offers the potential to compare the imaging benefit of 0.55NA to the established 0.33NA, through aerial image analysis of dedicated mask patterns. The recently available capability of high-NA imaging on AIMS® EUV was applied to compare options for imec’s logic patterning roadmap, specifically for tip-to-tip structures (T2T). Beyond direct comparison of 0.33 and 0.55 NA, low-n absorber was compared to conventional Ta-based absorber. Moreover, in view of anamorphic imaging at high-NA, T2T pattern orientation was compared, i.e., either along the 4X exposure slit direction or along the 8X scan direction. Lastly pattern tonality, i.e., darkfield versus lightfield, were evaluated side by side. The comparisons were made for selected, yet not optimized, dipole-like sources. Beyond normalized intensity log-slope (NILS) for the line-space part, the through-focus analysis comprised ILS and required bias for shrinking T2T size. The results show that 0.55NA provides clear advantages, but their variation among absorber type, T2T pattern orientation and tonality highlight the potential of preferred combinations. Such are suggested as starting points for further optimization.
OPC model accuracy is an important contributor to the EPE budget in the latest lithography nodes. The overall OPC accuracy depends on accurate calibration of the sub-models capturing mask, optical, resist and etch effects. The advent of high-NA (0.55) EUV lithography with anamorphic imaging has further increased the emphasis on accurate aerial image model calibration for computational lithography. In this paper, we study the feasibility of using direct aerial image measurements with the ZEISS AIMS EUV tool for improving OPC model accuracy as well as accurate metrology of mask pattern variability, which are both relevant to EPE budgeting.
AIMS® EUV is a unique tool in the EUV mask infrastructure. It allows qualification of the mask printing performance in the aerial image under scanner equivalent conditions. For emulation of the high NA EUV scanner, ZEISS upgraded the existing 0.33 NA AIMS® EUV platform. The system can now emulate both 0.33 NA isomorphic scanners as well as 0.55 NA anamorphic scanners. We present the concept of AIMS® EUV high NA with focus on the emulation of a wafer defocus in the anamorphic high NA scanner. Besides defect review applications, this enables aerial image based high NA imaging studies.
During the last decade, the introduction of EUV lithography in high-volume chip manufacturing has been accompanied by the development of technological prerequisites for a future support of the node scaling roadmap. As core element, the next generation EUV scanner with an increased NA of 0.55 will be implemented into wafer fabs within the upcoming few years. In addition to its enhanced resolution, the High-NA exposure tool improves image contrast, and consequently reduces local CDU and defect printing on wafer. To take full advantage of this next leap in lithography, the whole infrastructure including EUV photomask technologies and metrology must keep pace with the scanner progress. In this context, actinic EUV mask measurement represents a unique and variously usable way for the qualification of the mask printing performance under scanner-equivalent conditions. The aerial image metrology is targeted to match the corresponding scanner aerial image by means of the emulation of imaging-relevant scanner properties including wavelength, mask-side NA, through-slit chief ray angle, illumination schemes, and aberration level. To qualify High-NA masks of the anamorphic scanner, a methodology was developed that allows the simultaneous measurement of both NA=0.33 and NA=0.55 reticles based on one isomorphic optical projection optics design. Here, we describe the challenges and corresponding solutions combined with two intrinsically diverse emulation types, NA=0.33 isomorphic and NA=0.55 anamorphic, in one single metrology. Special attention is paid to the emulation of the elliptical scanner NA at reticle, the contrast impact due to vector-effects in High-NA scanner imaging, wafer defocus of an anamorphic system for focus-dose process window determination, the pupil obscuration of the High-NA scanner projection optics, and the scanner facetted illumination by means of physical free-form blades, and by a completely digital solution.
Digital Flex Illu is a fully digital solution which provides SMO functionality to the AIMS® EUV system by combining an adaptation of the already built-in system metrology with a powerful algorithm and most importantly, without changing the machine hardware. In this paper, we will present the concept of Digital Flex Illu functionality, its significant advantages in combination with a binary aperture-based illumination concept, together with showing imaging results obtained on the AIMS® EUV prototype system. This digital solution is a paradigm change for the AIMS® EUV usability and final user, it allows ZEISS to guarantee an agile roadmap for the AIMS® EUV with limited development effort and great benefits in sustainability and roadmap scaling.
DUV lithography has successfully adopted both bright and dark mask tonalities. This gives the freedom to chip manufacturers to choose the optimum combination of mask and resist tonality for their product [1]. In EUV lithography, however, there has been a clear preference for dark field masks, driven by the prevalence of positive tone resist processes, and their relative insensitivity to multilayer defects. Future customer nodes, however, may require negative tone (metal-oxide) resist processes [2][3], resulting in a requirement to use bright field masks. Therefore, a deeper understanding of bright and dark field imaging is needed in order to provide guidance to ASML customers in choosing the optimal approach. In this work we consider the fundamentals of bright and dark field imaging based on the diffraction theory of aerial image formation [4]. We will show that bright field imaging has an intrinsic potential for higher optical NILS (normalized image log-slope), especially for isolated features, but with a lower depth of focus. The theoretical results are compared to rigorous simulations. Experimental bright vs dark-field results is also presented for comparison. Wafer based data has been obtained on an NXE:3400 scanner, whilst aerial image measurements have been obtained using the Aerial Image Measurement System for EUV (AIMS® EUV) at Zeiss. These experimental results confirm the theoretical expectations. The main goal of the paper is to draw attention to bright versus dark field comparison for EUV and to kick off more studies in this direction.
Scaling trends in the semiconductor industry towards smaller technology nodes and feature sizes are continuing and first consumer products manufactured with the help of EUV technology are already on the market. Major industrial players have introduced EUV lithography into their production at the 7nm technology node and with the 5nm node being on its way [1], the amount of EUV lithographic layers is expected to rise significantly and implementation of EUV double patterning is anticipated. These developments lead to more strict technological requirements especially for the corresponding EUV but also for the used high-end DUV photomasks in terms of minimum feature sizes and acceptable Edge Placement Errors (EPE). Moreover, photomask defectivity increases dramatically with shrinking feature sizes. This creates significant challenges to the industry, as in particular the most cost intensive EUV photomasks possess the highest numbers of defects. The current industry standard for high-end photomask repair tools is the MeRiT neXT [2]. To face the upcoming challenges an efficient and reliable way to repair future high-end photomasks is inevitable. A corresponding repair tool must address decreased minimum feature sizes and increased pattern complexity on high-end photomasks. In this paper we present our latest results of high-end EUV repairs carried out on the next generation photomask repair tool MeRiT LE. The tool shows improved system dynamics, makes use of a new electron beam column, which operates at a low electron beam voltage down to 400V and enables the repair of next generation ultra-small defects.
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