The subject invention relates to optical devices used to non-destructively evaluate semiconductor wafers. In particular, the present invention relates to methods for characterizing ultra shallow junctions in semiconductors.
As semiconductor geometries continue to shrink, manufacturers have increasingly turned to optical techniques to perform non-destructive inspection and analysis of semiconductor wafers. Optical techniques typically apply an incident beam (often referred to as a probe beam) to a sample and then detect and analyze the reflected energy. This type of inspection and analysis is known as optical metrology and is performed using a range of different optical techniques.
One widely used type of optical metrology is known as photo modulated reflectance or PMR. As shown in
The presence of the thermal and plasma waves has a direct effect on the surface reflectivity of the sample. Features and regions below the sample surface that alter the passage of the thermal and plasma waves will therefore alter the optical reflective patterns at the surface of the sample. By monitoring the changes in reflectivity of the sample at the surface, information about characteristics below the surface can be obtained.
To monitor the surface changes, a probe laser is used to direct a probe beam at a portion of the sample that is excited by the pump laser. The sample reflects the probe beam and a photodetector records the intensity of the reflected probe beam. The output signal from the photodetector is filtered to isolate the changes that are synchronous with the pump beam modulation. For most implementations, this is performed using a heterodyne or lock-in detector (See U.S. Pat. No. 5,978,074 and in particular
Amplitude=√{square root over (I2+Q2)} (1)
Phase=arctan(Q/I) (2)
The amplitude and phase values are used to deduce physical characteristics of the sample. In most cases, this is done by measuring amplitude values (amplitude is used more commonly than phase) for one or more specially prepared calibration samples, each of which has known physical characteristics. The empirically derived values are used to associate known physical characteristics with corresponding amplitude values. Amplitude values obtained for test samples can then be analyzed by comparison to the amplitude values obtained for the calibration samples.
Characterization of samples using I and Q outputs is described in U.S. patent application Ser. No. 10/387,259, filed Mar. 12, 2003, assigned to the same assignee and incorporated here by reference. In this case, experimentally obtained in-phase and quadrature signals are plotted in I-Q coordinates, analyzed, and compared to calibration data.
The PMR-type system shown in
As part of the manufacturing process, ions (or dopants) are added to the near-surface region of semiconductors using a process known as implantation. The implanted region (with its relatively high dopant concentration) overlays a non-implanted region where dopant concentrations are relatively low. The transition between the implanted region and the non-implanted region is commonly referred to as a junction. For advanced semiconductor manufacturing, it is generally desirable for the implanted region to be shallow, typically 500 Å or less. Devices of this type are generally referred to as having ultra-shallow junctions or USJ.
The quality of USJ wafers (and the processes used to create USJ wafers) is typically assessed using two parameters: junction depth and junction abruptness. Junction depth (Xj) is the depth at which the junction between the implanted and non-implanted regions is located. Abruptness (measured in nm/dec) characterizes how quickly the junction transitions between high level and low level dopant concentrations. To illustrate,
In practice, shallow junction depth is typically accomplished by implantation at high dopant dose and low energy. Abruptness is typically achieved using a rapid thermal annealing (RTA) process. In practice, the required junction depth is often relatively easy to achieve. However, keeping the USJ profile abrupt and close to the surface after anneal is a big challenge. As a result, techniques to measure junction depth and abruptness are critical for the manufacture of USJ semiconductors.
Incompleteness of anneal is another parameter that is crucial to USJ characterization. Incompleteness appears when non-uniformities in structural damage caused by ion implantation along with malfunctioning of the RTA process and other types of annealing processes result in residual structural damage areas on the surface of a semiconductor wafer after anneal. This incomplete anneal should also be monitored to increase manufacturing yield and to ensure high performance characteristics of a semiconductor device.
A number of techniques have been developed to characterize the effectiveness of USJ processes. Destructive and contact techniques include secondary ion mass spectroscopy (SIMS), transmission electron microscopy (TEM), and spreading resistance depth profiling (SRP). These methods are capable of providing detailed USJ profile information, but at the expense of a turnaround time that is usually measured in days or even weeks or at the expense of damaging the surface with contacts. Alternately, U.S. patent application Ser. No. 09/799,481 (published as U.S. 2002/0167326) describes a non-destructive method for measuring profile abruptness. According to this method, several amplitude measurements are taken at different powers of the pump laser in a photothermal system similar to that described above. The resulting power dependencies are than fitted to a function (power series) and the second (quadratic) coefficient of that function is correlated to profile abruptness.
The present invention offers a series of methods for characterizing USJ profiles including methods for characterizing depth, abruptness, and anneal incompleteness. To measure USJ profile abruptness, a PMR-type optical metrology tool is used to perform a series of two or more measurements. The separation between the pump and probe beams is changed for each successive measurement. Typically, this means that measurements are obtained, for example, at zero (coincident pump and probe beams) and one μm beam separation. At each separation, quadrature (Q) and in-phase (I) measurements are obtained.
A line is then fitted to the measurements in the I-Q plane. The slope of that line corresponds to the abruptness of the sample being analyzed. To determine the exact correspondence, a calibration phase is typically used where a similar slope is obtained for a sample having a known USJ profile. Abruptness can then be computed by comparing the slope associated with the known sample to slope information obtained for samples under test.
For a second implementation of the abruptness measuring method, the pump and probe beams are maintained a fixed separation. The power density provided by the pump beam is altered for each successive measurement. I and Q values are obtained for each measurement and used to derive a corresponding slope in I-Q space. The slope is compared to a similar slope associated with a known USJ profile to determine abruptness.
To measure USJ profile depth, a PMR-type optical metrology tool is used to perform a series of one or more measurements. Quadrature (Q) measurements are obtained for each measurement and are linearly scaled (typical using a table or other lookup mechanism) to derive USJ profile depth values.
To measure anneal incompleteness, a PMR-type optical metrology tool is developed which provides a “decay factor” stationary mapping. Each measurement is performed stationary along the wafer. During each measurement, the reflected probe beam intensity is monitored and recorded as a function of time. Changes in the measured probe beam over time characterize the anneal performance. The “decay factor” at each measurement is calculated as the ratio of the signal from an initial point (typically when the pump beam is initially focused on the sample under test) to the signal at some subsequent point (typically a defined interval such as ten seconds). The decay factor is typically defined to be close to unity when the sample tested is completely annealed. For wafers having residual damage, the decay factor will be greater or less than unity. A complete map of the annealing behavior of the wafer can be provided in terms of “decay factor” values.
The methods described above are intended to be used separately or in combination. They may be used to perform single inspections of multiple measurements within the same sample. Multiple measurements are especially useful to map a parameter (decay factor, USJ depth or USJ profile) for all or a portion of a sample. Multiple measurements may also be used to derive average and standard deviation values for any of the three parameters.
The present invention includes a series of methods for characterizing USJ profiles. As will be described in the following sections, this includes methods for characterizing USJ abruptness, USJ depth and anneal incompleteness.
USJ Abruptness Variable Beam Separation Method
To measure profile abruptness, a PMR system of the type generally shown in
The measurements obtained at the different separations are analyzed in I-Q space. To illustrate,
It should be noted that the slope information is not a direct measurement of abruptness—the values of 8.2 nm and 9.6 nm per decade shown in
In the measurement phase, one or more samples are measured using the PMR system to obtain the slope information as shown in
USJ Abruptness, Variable Power Density Method
Instead of varying pump and probe beam separation, another approach is to vary pump beam power density. The present invention provides a second method for measuring profile abruptness that uses this approach. In the case of the second method, I and Q measurements are taken on a sample at two or more pump beam power densities. In a preferred embodiment pump power density is changed (decreased) by inserting a neutral filter into the optical path of the pump beam. In an alternative embodiment, the pump power density is changed by changing the pump beam spot size. As before, the resulting I and Q measurements are plotted in I-Q space. A line is then fitted to the measurements and the slope of the line is extracted and correlated to USJ profile abruptness measured independently using another (typically destructive) technique. This correlation is used to determine abruptness on other wafers with unknown parameters.
It should be noted that, despite of their similarity in using I-Q space, the two methods described above are based on quite different physical assumptions and experimental geometries. These methods might have different sensitivities to a variety of junction properties, other than profile abruptness (dopant nature and concentration, inhomogeneities, etc.). It might be advantageous to use both methods in combination to obtain more reliable abruptness data. In addition, USJ profiles can have different abruptness at different concentration levels. For example, in
An important feature of both measurement methods (power density and pump-probe beam separation) is the ability to obtain measurements rapidly. In fact, it is entirely practical to make multiple abruptness measurements at different locations within the sample under test even in production environments.
It should be understood that the methods of the present invention is not limited to the combination of I and Q values obtained directly from the experiment, and may use any combination of these parameters that is beneficial.
USJ Depth, PMR Q Data Method
To measure USJ depth, a PMR system of the type generally shown in
The Q data obtained from each sample is used to derive corresponding USJ depth measurements. Typically, this is done using a correlation table that maps Q data to USJ depth. Other implementations may use other methods to correlate Q data to depth measurements.
As shown in
As can be clearly seen in
To conclude this section, it is noted that the depth measurement method provided by the present invention allows for precise measuring of an average USJ junction depth and high-resolution depth distribution mapping across the surface of the wafer in a short time, thus comparing favorably with time-consuming and destructive single-point SIMS analysis.
Characterization of Anneal
To measure anneal incompleteness and/or surface electronic states, a PMR system of the type generally shown in
The recorded TW signal is used to develop a curve which is then fitted to an exponential decay.
The DF parameter characterizes completeness of the anneal process and/or the presence of surface states at the location where it is recorded. The closer DF is to unity, the better is the quality of the annealing process.
It should also be noted that the measurement methods of the present invention may be used separately to measure any of the described parameters. The methods may also be used to characterize all three parameters for a single sample. This is shown in
The present application claims priority to U.S. Provisional Patent Application Ser. No. 60/477,255, filed Jun. 10, 2003, and U.S. Provisional Patent Application Ser. No. 60/496,117, filed Aug. 19, 2003, the disclosures of which are incorporated in this document by reference.
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