Scatterometry for contact hole lithography

Scatterometry has been most commonly applied to CD metrology of line/space grating structures. However, for the process development and control of 3D structures for contact hole lithography applications, the current metrology methods of CD-SEM, electrical CD (ECD) and/or cross-sectional SEM (X-SEM) produce the desired information either (a) as an incomplete solution, (b) too late in process flow, or (c) in a destructive manner. In this paper, we will present use cases for the application of scatterometry to 3D structures, i.e., post-lithography hole/space patterns, where measurements of CD, profile, and film thickness can be made immediately following the lithography process, in a method nondestructive to the wafer. These use cases demonstrate the capability of 3D metrology integrated onto a TEL Clean Track platform, where a Therma-Wave reflectometer was used to generate spectra that were then processed via Timbre ODP, for a film stack of patterned photoresist (PR), anti-reflective coating (ARC), and oxide on top of a silicon (Si) substrate. Focus-Exposure Matrix (FEM) wafers have also been produced in order to characterize the contact hole profile and CD variation as a result of changing focus and exposure conditions. The results of the experiment show that ODP can be used successfully to monitor CD, film thickness, and profile variation, providing a valuable solution to contact hole lithography. Tool precision and matching results are also shown, which indicate the stability of the measurement process, and correlation to CD-SEM is also provided as a reference metrology. These results suggest that integrated 3D scatterometry is a viable production metrology solution, enabling the progression toward Advanced Process Control (APC).