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Effective Lithography Defect Monitoring Ingrid Peterson, Louis Breaux, Andrew Cross, and Mike von den Hoff, KLA-Tencor Corporation

As minimum dimensions and process windows decrease in the lithography area, new technologies and technological advances with resists and resist systems are being implemented to meet the demands. Along with these new technological advances in the lithography area come potentially unforeseen defect issues.

Introduction

The latest lithography processes involve new resists in extremely thin, uniform films, exposing the films under highly optimized focus and illumination conditions and, finally, removing the resist completely and cleanly. The lithography cell is defined as the cluster of process equipment that accomplishes the coating process (surface prep, resist spin, edge-bead removal and soft bake), the alignment and exposure, and the developing process (post-exposure bake, develop, rinse) of the resist. Often, the resist spinning process involves multiple materials such as bottom anti-reflective coating (BARC) and/or top anti-reflective coating (TARC) materials in addition to the resist. The introduction of these new materials Too Wide EBR together with the multiple materials interfaces and the Exposure tightness of the process Non-Uniformity windows lead to an increased variety of defect mechanisms in the lithogSolvent Drips raphy area. Defect management in the lithography Residues area has become critical to successful product introduction and yield ramp. Striations The semiconductor process itself contributes the largest number and variety of defects, and a significant

portion of the total defects originate within the lithography cell. From a defect management perspective, the lithography cell has some unique characteristics. First, defects in the lithography process module have the widest range of sizes, from full-wafer to sub-optical, and with the largest variety of characteristics. Some of these defects fall into the categories of coating problems, focus and exposure defects, developer defects, edge-bead removal problems, contamination and scratches usually defined as lithography macro defects (Figure 1). Others fall into the category of lithography micro defects (Figure 2). They are characterized as having low topography such as stains, developer spots, satellites, and very small defects such as micro-bridging, partial micro-bridging, micro-bubbles, CD variation and single isolated missing or deformed contacts or vias.

Scribe or Array Placement Resist Bubbles

Field Tilt

Comets

Particles

Hot Spots

Off-Center Resist Dispense

F i g u re 1. Examp les of lithogra phy “mac ro� defects.

Summer 2003

Yield Management Solutions

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