EUV exposures at the SEMATECH Berkeley Microfield Exposure Tool have demonstrated patterning down to 15 nm half pitch in a chemically amplified resist at a dose of 30 mJ/cm2. In addition, the sensitivity of two organic chemically amplified EUV resists has been measured at 6.7 nm and 13.5 nm and the sensitivity at 6.7 nm is shown to be a factor of 6 lower than the sensitivity at 13.5 nm. The reduction of the sensitivity of each resist at 6.7 nm relative to the sensitivity at 13.5 is shown to be correlated to a reduction of the mass attenuation coefficients of the elements involved with photoabsorption.

Although Extreme ultraviolet lithography (EUVL) is now well into the commercialization phase, critical challenges remain in the development of EUV resist materials. The major issue for the 22-nm half-pitch node remains simultaneously meeting resolution, line-edge roughness (LER), and sensitivity requirements. Although several materials have met the resolution requirements, LER and sensitivity remain a challenge. As we move beyond the 22-nm node, however, even resolution remains a significant challenge. Chemically amplified resists have yet to demonstrate the required resolution at any speed or LER for 16-nm half pitch and below. Going to non-chemically amplified resists, however, 16-nm resolution has been achieved with a LER of 2 nm but a sensitivity of only 70 mJ/cm(2).

Several high-performing resists identified in the past two years have been exposed at the 0.3-numerical-aperture (NA) SEMATECH Berkeley Microfield Exposure Tool (BMET) with an engineered dipole illumination optimized for 18-nm half pitch. Five chemically amplified platforms were found to support 20-nm dense patterning at a film thickness of approximately 45 nm. At 19-nm half pitch, however, scattered bridging kept all of these resists from cleanly resolving larger areas of dense features. At 18-nm half pitch, none of the resists were are able to cleanly resolve a single line within a bulk pattern. With this same illumination a directly imageable metal oxide hardmask showed excellent performance from 22-nm half pitch to 17-nm half pitch, and good performance at 16-nm half pitch, closely following the predicted aerial image contrast. This indicates that observed limitations of the chemically amplified resists are indeed coming from the resist and not from a shortcoming of the exposure tool. The imageable hardmask was also exposed using a Pseudo Phase-Shift-Mask technique and achieved clean printing of 15-nm half pitch lines and modulation all the way down to the theoretical 12.5-nm resolution limit of the 0.3-NA SEMATECH BMET.

Several high-performing resists identified in the past two years have been exposed at the 0.3-numerical-aperture (NA) SEMATECH Berkeley Microfield Exposure Tool (BMET) with an engineered dipole illumination optimized for 18-nm half pitch. Five chemically amplified platforms were found to support 20-nm dense patterning at a film thickness of approximately 45 nm. At 19-nm half pitch, however, scattered bridging kept all of these resists from cleanly resolving larger areas of dense features. At 18-nm half pitch, none of the resists were are able to cleanly resolve a single line within a bulk pattern. With this same illumination a directly imageable metal oxide hardmask showed excellent performance from 22-nm half pitch to 17-nm half pitch, and good performance at 16-nm half pitch, closely following the predicted aerial image contrast. This indicates that observed limitations of the chemically amplified resists are indeed coming from the resist and not from a shortcoming of the exposure tool. The imageable hardmask was also exposed using a Pseudo Phase-Shift-Mask technique and achieved clean printing of 15-nm half pitch lines and modulation all the way down to the theoretical 12.5-nm resolution limit of the 0.3-NA SEMATECH BMET.

As commercialization of extreme ultraviolet lithography (EUVL) progresses, direct industry activities are being focused on near term concerns. The question of long term extendibility of EUVL, however, remains crucial given the magnitude of the investments yet required to make EUVL a reality. Extendibility questions are best addressed using advanced research tools such as the SEMATECH Berkeley microfield exposure tool (MET) and actinic inspection tool (AIT). Utilizing Lawrence Berkeley National Laboratory's Advanced Light Source facility as the light source, these tools benefit from the unique properties of synchrotron light enabling research at nodes generations ahead of what is possible with commercial tools. The MET for example uses extremely bright undulator radiation to enable a lossless fully programmable coherence illuminator. Using such a system, resolution enhancing illuminations achieving k1 factors of 0.25 can readily be attained. Given the MET numerical aperture of 0.3, this translates to an ultimate resolution capability of 12 nm. Using such methods, the SEMATECH Berkeley MET has demonstrated resolution in resist to 16-nm half pitch and below in an imageable spin-on hard mask. At a half pitch of 16 nm, this material achieves a line-edge roughness of 2 nm with a correlation length of 6 nm. These new results demonstrate that the observed stall in ultimate resolution progress in chemically amplified resists is a materials issue rather than a tool limitation. With a resolution limit of 20-22 nm, the CAR champion from 2008 remains as the highest performing CAR tested to date. To enable continued advanced learning in EUV resists, SEMATECH has initiated a plan to implement a 0.5 NA microfield tool at the Advanced Light Source synchrotron facility. This tool will be capable of printing down to 8-nm half pitch.

Microfield exposure tools (METs) play a crucial role in the development of extreme ultraviolet (EUV) resists and masks. One of these tools is the SEMATECH Berkeley 0.3 numerical aperture (NA) MET. Using conventional illumination this tool is limited to approximately 22-nm half pitch resolution. However, resolution enhancement techniques have been used to push the patterning capabilities of this tool to half pitches of 18 nm and below. This resolution was achieved in a new imageable hardmask which also supports contact printing down to 22 nm with conventional illumination. Along with resolution, line-edge roughness is another crucial hurdle facing EUV resists. Much of the resist LER, however, can be attributed to the mask. We have shown that intenssionally aggressive mask cleaning on an older generation mask causes correlated LER in photoresist to increase from 3.4 nm to 4.0 nm. We have also shown that new generation EUV masks (100 pm of substrate roughness) can achieve correlated LER values of 1.1 nm, a 3x improvement over the correlated LER of older generation EUV masks (230 pm of substrate roughness). Finally, a 0.5-NA MET has been proposed that will address the needs of EUV development at the 16-nm node and beyond. The tool will support an ultimate resolution of 8 nm half-pitch and generalized printing using conventional illumination down to 12 nm half pitch.

The problem of carbon contamination on extreme ultraviolet (EUV) optics, causing unacceptably low reflectivity in mirrors, must be solved before industry will adopt the technology on a production scale. Breaking vacuum, removing and then cleaning mirrors is a time-consuming and expensive method for dealing with the problem. A safe yet effective in situ method for cleaning EUV optics and maintaining vacuum chamber cleanliness is important for progress in EUV lithography. Carbon contamination has also been a problem for the scanning electron microscopes (SEMs) leading to reduced image quality. The use of low power downstream plasma cleaner has been shown to be effective in removing carbon contamination from SEMs. The plasma dissociates oxygen molecules into neutral oxygen radicals. These radicals flow throughout the SEM vacuum chamber and chemically remove the carbon contamination. Since the process works by chemical etch and not by sputter etch, the capping layer on EUV mirrors will not be damaged by the cleaning process. The production of chemically etching oxygen radicals by plasma cleaning was measured using a quartz crystal microbalance. The effectiveness of the downstream plasma cleaning process was also tested on EUV mirrors.

To accurately estimate the flare contribution from the out-of-band (OOB), the integration of a DUV source into the SEMATECH Berkeley 0.3-NA Micro-field Exposure tool is proposed, enabling precisely controlled exposures along with the EUV patterning of resists in vacuum. First measurements evaluating the impact of bandwidth selected exposures with a table-top set-up and subsequent EUV patterning show significant impact on line-edge roughness and process performance. We outline a simulation-based method for computing the effective flare from resist sensitive wavelengths as a function of mask pattern types and sizes. This simulation method is benchmarked against measured OOB flare measurements and the results obtained are in agreement.

Microfield exposure tools continue to play a dominant role in the development of extreme ultraviolet (EUV) resists. Here we present an update on the SEMATECH Berkeley 0.3-NA microfield exposure tool and summarize the latest test results from high-resolution line-space printing. Printing down to 20-nm is presented with large process latitude at 22-nm half-pitch lines. Also presented are line-edge roughness results along with a discussion of the importance of mask contributors to line-edge roughness measured in resist. Finally we briefly describe an upgrade to the tool that will enable EUV resist development at the 16-nm half-pitch node and beyond. (This paper was presented in MNE 2008 conference, , ).

Microfield exposure tools (METs) continue to play a dominant role in the development of extreme ultraviolet resists. One of these tools is the 0.3 numerical aperture SEMATECH Berkeley MET operating as a resist and mask test center. Here the authors present an update on this tool, summarizing the latest test and characterization results. They provide an update on the long-term aberration stability of the tool and present line-space imaging in chemically amplified photoresist down to the 20nm half-pitch level. Although resist development has shown substantial progress in the area of resolution, line edge roughness (LER) remains a significant concern. In this manuscript the authors further present a summary of recent LER performance results and consider the effect of mask contributors to the LER observed from the SEMATECH Berkeley MET.

Microfield exposure tools (METs) continue to play a dominant role in the development of extreme ultraviolet (EUV) resists. One of these tools is the SEMATECH Berkeley 0.3-NA MET operating as a SEMATECH resist and mask test center. Here we present an update summarizing the latest resist test and characterization results. The relatively small numerical aperture and limited illumination settings expected from 1st generation EUV production tools make resist resolution a critical issue even at the 32-nm node. In this presentation, sub 22 nm half pitch imaging results of EUV resists are reported. We also present contact hole printing at the 30-nm level. Although resist development has progressed relatively well in the areas of resolution and sensitivity, line-edge-roughness (LER) remains a significant concern. Here we present a summary of recent LER performance results and consider the effect of system-level contributors to the LER observed from the SEMATECH Berkeley microfield tool.

Microfield exposure tools (METs) have and continue to play a dominant role in the development of extreme ultraviolet resists and masks. One of these tools is the SEMATECH Berkeley 0.3 numerical aperture (NA) MET. Here, the authors investigate the possibilities and limitations of using the 0.3 NA MET for sub-22-nm half-pitch development. They consider mask resolution limitations and present a method unique to the centrally obscured MET, allowing mask patterning resolution limitations to be overcome. The method, however, comes at the cost of increased sensitivity to mask surface roughness. They also explore projection optics resolution limits and describe various illumination schemes allowing resolution enhancement. At 0.3 NA, the 0.5k(1) factor resolution limit is 22.5 nm, meaning that conventional illumination is of limited utility for sub-22-nm development. In general, resolution enhancing illumination encompasses increased coherence. They study the effect of this increased coherence on line-edge roughness (LER), which, along with resolution, is another crucial factor in sub-22-nm resist development. Due to coherence induced LER limitations, addressing the development at 16 nm half pitch and beyond will ultimately require higher NA systems.

Microfield exposure tools (METs) continue to play a dominant role in the development of extreme ultraviolet (EUV) resists. Here we present an update on the SEMATECH Berkeley 0.3-NA MET and summarize the latest test results from high-resolution line-space and contact-hole printing. In practice, the resolution limit of contact-hole printing is generally dominated by contact size variation that is often speculated to originate form shot noise effects. Such observations of photon-noise limited performance are concerning because they suggest that future increased resist sensitivity would not be feasible. Recent printing data, however, indicates that the contact size variation problem is currently not a result of shot noise but rather attributable to the mask in combination with the resist-dominated mask error enhancement factor (MEEF). Also discussed is the importance of the contribution of the system-level line-edge roughness (LER) to resist LER values currently obtained with the SEMATECH Berkeley MET. We present the expected magnitude of such effects and compare the results to observed trends in LER performance from EUV resists over the past few years.

Illumination uniformity and reproducibility in extreme ultraviolet (EUV) microfield exposure tools are critical to many aspects of the EUV lithography development task. Here, the authors present a scanning-field-averaging illuminator delivering consistent, uniform illumination to synchrotron-based microfield exposure tools. The system is integrated into the existing Fourier-synthesis custom coherence illuminator at the SEMATECH Berkeley microfield exposure tool and its effectiveness is demonstrated lithographically. Following the upgrade, the authors report a 6.5% peak-to-valley intensity variation across the full 200×600μm2 wafer-side field of view.

Recent upgrades made to the SEMATECH Berkeley microfield exposure tool are summarized and some of the latest resist characterization results are presented. Tool illumination uniformity covering the full 200×600μm2 wafer-side field of view is demonstrated and intrawafer focus control of 1.8nm is shown. Printing results demonstrate chemically amplified resist resolution of 28nm dense and 22.7nm semi-isolated. Moreover, contact printing results show that shot noise is not a dominant issue in current 35nm contact printing performance.

Author(s): Naulleau, Patrick P.; Anderson, Chris N.; Dean, Kim; Denham, Paul; Goldberg, Kenneth A.; Hoef, Brian; Fontaine, Bruno La; Wallow, Tom

Operating as a SEMATECH resist test center, the Berkeley 0.3-NA EUV microfield exposure tool continues to play a crucial role in the advancement of EUV resists and masks. Here we present recent resist-characterization results from the tool as well as tool-characterization data. In particular we present lithographic-based aberration measurements demonstrating the long-term stability of the tool. We also describe a recent upgrade to the tool which involved redesign of the programmable coherence illuminator to provide improved field uniformity as well as a programmable field size.

Extreme ultraviolet lithography is a leading candidate for volume production of nanoelectronics at the 32-nm node and beyond. In order to ensure adequate maturity of the technology by the start date for the 32-nm node, advanced development tools are required today with numerical apertures of 0.25 or larger. In order to meet these development needs, a microexposure tool based on SEMATECH's 0.3-numerical aperture microfield optic has been developed and implemented at Lawrence Berkeley National Laboratory, Berkeley, CA. Here we describe the Berkeley exposure tool in detail, discuss its characterization, and summarize printing results obtained over the past year. Limited by the availability of ultrahigh resolution chemically amplified resists, present resolving capabilities limits are approximately 32 nm for equal lines and spaces and 28 nm for semi-isolated lines.

We report on a method to produce any type of phase-shift masks for EUV lithography. We have successfully fabricated an unattenuated phase-shift mask consisting of phase patterns and confirmed the expected performance of such a mask through resist printing at lambda=13.3 nm. Finally actinic metrology reveals that these etched-multi layer masks, left without a capping layer, tend to degrade over time.

The past two years has brought tremendous improvements in the crucial area of resists for extreme ultraviolet (EUV) lithography. Nested and isolated line resolutions approaching 30 nm and 25 nm, respectively, have been demonstrated. These advances have been enabled, in large part, by the high-numerical (0.3) EUV imaging capabilities provided by the Berkeley microfield exposure tool (MET). Here we investigate the resolution limits in several advanced EUV resists using the Berkeley MET. Comparisons to aerial-image performance and the use of resolution-enhancing illumination conditions are used to establish the fact that the observed pattern resolution in the best chemically-amplified resists available today are indeed resist limited. Moreover, contrast transfer function (CTF) techniques are used to directly compare various advanced resists. Strong correlation is observed between relative CTF performance and observed resolution limits.