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April - June 2012

Volume 11, Issue 2 (partial)

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Extreme-ultraviolet source specifications: tradeoffs and requirements

Roel Moors, Vadim Banine, Geert Swinkels, and Frans Wortel

J. Micro/Nanolith. MEMS MOEMS 11, 021102 (May 21, 2012); http://dx.doi.org/10.1117/1.JMM.11.2.021102

Online Publication Date: May 21, 2012

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Although progress has been reported, the extreme-ultraviolet (EUV) source remains one of the largest challenges for EUV lithography production to be economically viable. This article gives an update on the high-level source requirements, including the origin of these specifications. All requirements are driven by litho system cost-of-ownership considerations and the imaging capabilities. Attention will be paid to conflicting requirements and the consequent tradeoffs that have to be made in making conceptual source decisions and in designing an EUV system. Finally, we will look into the future of the top-level source requirements with the conclusions that not only EUV power requirements will keep on increasing, but that this increase has to be accompanied with a high availability and reliability of the source. Furthermore, an operation mode has to be found that is chemically, particulately, and spectrally clean so that the cost-of-ownership and imaging capabilities of the total system remain intact over its lifetime.

New type of discharge-produced plasma source for extreme ultraviolet based on liquid tin jet electrodes

Konstantin Koshelev, Vladimir Krivtsun, Vladimir Ivanov, Oleg Yakushev, Alexey Chekmarev, Vsevolod Koloshnikov, Evegenii Snegirev, and Viacheslav Medvedev

J. Micro/Nanolith. MEMS MOEMS 11, 021103 (May 16, 2012); http://dx.doi.org/10.1117/1.JMM.11.2.021103

Online Publication Date: May 16, 2012

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A new approach for discharge-produced plasma (DPP) extreme ultraviolet (EUV) sources based on the usage of two liquid metallic alloy jets as discharge electrodes has been proposed and tested. Discharge was ignited using laser ablation of one of the cathode jets. A system with two jet electrodes was tested at a repetition rate of 1 to 5 kHz with dissipated electrical power up to 20 kW. Radiating spectra, time characteristics, and conversion efficiency are similar to conventional DPP schemes with rotating wheels. In the first experiments, the Ga:Sn eutectic alloy, which is liquid at room temperature, was circulating in a closed loop. The high velocity of the jets (30  m/s) ensures a renewed electrode surface for every shot, for a repetition rate frequency of up to 30 to 50 kHz, and provides effective heat transportation from the discharge zone. Modeling and experiments demonstrate that the proposed scheme is able to dissipate up to 200 kW of electrical power without overheating the nozzles and tin surface. It was found that the flexible electrode configuration allows the channeling of essential parts of debris plasma in directions opposite to the EUV collector.

Extreme-ultraviolet light source development to enable pre-production mask inspection

Matthew J. Partlow, Matthew M. Besen, Paul A. Blackborow, Ron Collins, Deborah Gustafson, Stephen F. Horne, and Donald K. Smith

J. Micro/Nanolith. MEMS MOEMS 11, 021105 (May 21, 2012); http://dx.doi.org/10.1117/1.JMM.11.2.021105

Online Publication Date: May 21, 2012

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As extreme-ultraviolet (EUV) lithography moves into pre-production, the requirement for commercially available mask metrology tools becomes more urgent. A key to developing a successful tool is a reliable, high-brightness EUV light source. The Energetiq EQ-10 is a commercially available EUV light source, with an installed base of over 15 sources in the field. The source relies on an electrodeless Z-pinch™ to produce greater than 10  Watts/2π of 13.5 nm 2% bandwidth light. In order to meet brightness and stability requirements of mask metrology tools, we have investigated modifications to the original design of the EQ-10. The result of these modifications has roughly doubled the source output power, and has achieved brightness greater than 8  Watts/mm2/sr, without sacrificing the spatial and pulse-to-pulse stability of the original design. This level of performance is sufficient for initial mask blank and imaging inspection tools.

Tin laser-produced plasma as the light source for extreme ultraviolet lithography high-volume manufacturing: history, ideal plasma, present status, and prospects

Toshihisa Tomie

J. Micro/Nanolith. MEMS MOEMS 11, 021109 (May 21, 2012); http://dx.doi.org/10.1117/1.JMM.11.2.021109

Online Publication Date: May 21, 2012

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Today intermediate-focus equivalent extreme ultraviolet (EUV) power of several watts is now available, and EUV lithography scanners are being considered as potential scanners for high-volume manufacturing (HVM) tools. However, for high-volume manufacturing with throughput of over 100 wafers per hour, EUV power of 350 W may be required. We review the history of EUV sources for lithography with tin as fuel. We discuss the ideal plasma for tin sources for extreme ultraviolet lithography (EUVL), conditions for a high conversion efficiency of 4% to 5% in 2πsr, and the existence of a repetition rate limit at around 40 kHz. We review the present status reported by EUV source suppliers and the prospects of tin laser-produced plasma as an EUV source for HVM EUVL.

Return-to-zero line code modeling of distributed tin targets for laser-produced plasma sources of extreme ultraviolet radiation

Konstantin N. Koshelev, Vladimir V. Ivanov, Vladimir G. Novikov, Viacheslav Medvedev, Alexander S. Grushin, and Vladimir M. Krivtsun

J. Micro/Nanolith. MEMS MOEMS 11, 021112 (May 21, 2012); http://dx.doi.org/10.1117/1.JMM.11.2.021112

Online Publication Date: May 21, 2012

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An integrated model is developed to describe the hydrodynamics, atomic, and radiation processes that take place in extreme ultraviolet (EUV) radiation sources based on a laser-produced plasma with a distributed tin target. The modeling was performed using the return-to-zero line code—a numerical code for the simulation of EUV emission by hot dense plasmas. The purpose of the simulation is to evaluate the spectral characteristics of the radiation source, conversion efficiency, source size, evaporation rate of the target, energetic, and space distribution of debris (nanoparticles, neutrals, and ions). The advantages of a distributed target in comparison with a single droplet target are also discussed.

Out-of-band radiation mitigation at 10.6 μm by molecular absorbers in laser-produced plasma extreme ultraviolet sources

Chimaobi Mbanaso, Alin Antohe, Horace Bull, Frank Goodwin, Ady Hershcovitch, and Gregory Denbeaux

J. Micro/Nanolith. MEMS MOEMS 11, 021116 (May 10, 2012); http://dx.doi.org/10.1117/1.JMM.11.2.021116

Online Publication Date: May 10, 2012

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Out-of-band radiation in extreme ultraviolet (EUV) exposure tools remains one of the critical issues that must be addressed before the implementation of this lithography technique for high-volume manufacturing. The out-of-band spectrum at the intermediate focus of EUV sources that use a CO2 laser-produced plasma is dominated by scattered radiation from the drive laser, which operates near 10.6-μm wavelength. To reduce the unwanted heating of optical components in the exposure tool caused by the infrared wavelength, a 10.6-μm wavelength-absorbing gas can be used to reduce the number of photons at this wavelength reaching the intermediate focus. Gaseous sulfur hexafluoride (SF6), whose υ3 infrared active mode is vibrationally excited by radiation around 10.6-μm wavelength, can be used to function as a molecular absorber and thus, mitigate part of the infrared radiation. In this work, the optical absorption of gaseous SF6 is experimentally investigated at the CO2 laser wavelengths close to 10.6 μm as well as the EUV wavelength. Various considerations affecting the use of a gas-based spectral filter are also discussed in this paper.

Atomic-hydrogen cleaning of Sn from Mo/Si and DLC/Si extreme ultraviolet multilayer mirrors

Wouter A. Soer, Maarten M. J. W. van Herpen, Martin J. J. Jak, Peter Gawlitza, Stefan Braun, Nikolay N. Salashchenko, Nikolay I. Chkhalo, and Vadim Y. Banine

J. Micro/Nanolith. MEMS MOEMS 11, 021118 (May 03, 2012); http://dx.doi.org/10.1117/1.JMM.11.2.021118

Online Publication Date: May 03, 2012

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We have investigated the use of atomic-hydrogen-based cleaning to remove Sn contamination from extreme ultraviolet (EUV) multilayer mirrors. Mo and Si surfaces were cleaned at a relatively slow rate due to catalyzed dissociation of tin hydride on these surfaces. Mo/Si mirrors with B4C and Si3N4 cap layers and DLC-terminated DLC/Si mirrors showed complete removal of 10 nm Sn in 20 sec with full restoration of EUV reflectance. In addition, a prolonged cleaning treatment of 300 sec of a DLC/Si mirror resulted in only a minor EUV peak reflection loss of 1.2% absolute and no significant changes in infrared reflectance.

Extreme ultraviolet lasers: principles and potential for next-generation lithography

Juerg E. Balmer, Davide Bleiner, and Felix Staub

J. Micro/Nanolith. MEMS MOEMS 11, 021119 (May 10, 2012); http://dx.doi.org/10.1117/1.JMM.11.2.021119

Online Publication Date: May 10, 2012

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Extreme ultraviolet (EUV) lasers in the wavelength range of ∼ 10 to 20 nm have matured to a point where dedicated applications such as at-wavelength inspection of extreme-ultraviolet lithography (EUVL) masks become possible on the laboratory scale. The authors briefly review the principles of plasma-based EUV lasers, the progress made so far, and the output characteristics of interest to the EUVL community.

Source for extreme ultraviolet lithography based on plasma sustained by millimeter-wave gyrotron radiation

Nikolay I. Chkhalo, Sergei V. Golubev, Dmitry Mansfeld, Nikolay N. Salashchenko, Leonid A. Sjmaenok, and Alexander V. Vodopyanov

J. Micro/Nanolith. MEMS MOEMS 11, 021123 (May 21, 2012); http://dx.doi.org/10.1117/1.JMM.11.2.021123

Online Publication Date: May 21, 2012

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An extreme-ultraviolet (EUV) source based on a low-pressure discharge sustained in a magnetic trap by the high-power millimeter-wave radiation under electron-cyclotron-resonance (ECR) conditions is discussed. Multiple charged ions are efficiently generated and excited in such a discharge (tin ions injected into the trap from a vacuum-arc discharge were used) and emit line radiation in the desired wavelength range. A radiation power of 50 W into a solid angle of 4π  sr in a wavelength range of 13.5  nm±1% and an efficiency of about 1% for the conversion of the microwave radiation absorbed in the plasma to the extreme ultraviolet radiation were achieved in the preliminary experiments. The article describes in detail the method of measuring EUV light emission power and background radiation. The emissivity of the plasma heated by gyrotron radiation with frequencies of 170 and 300 GHz is calculated. The proposed scheme can reduce the size of the emitting region up to ∼ 1  mm. The source can operate in both continuous and in pulsed mode.

Design of high brightness laser-Compton source for extreme ultraviolet and soft x-ray wavelengths

Kazuyuki Sakaue, Akira Endo, and Masakazu Washio

J. Micro/Nanolith. MEMS MOEMS 11, 021124 (May 03, 2012); http://dx.doi.org/10.1117/1.JMM.11.2.021124

Online Publication Date: May 03, 2012

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Design of a clean, high-brightness light source is presented for extreme ultraviolet/soft x-ray (EUV/SXR) lithography research and mask inspection. Basic characteristics of classical laser-Compton scattering are reviewed, and the laser and electron beam parameters at relatively low energy (EUV to SXR) photon generation are optimized. Recent achievements in each component technology are evaluated on a continuous wave (CW)-operated electron linac and energy recovery linac system, based on superconducting technologies at a 1.3 GHz operation frequency, 10 kW average power, short pulse CO2 laser, and optical super cavity with a 600- enhancement- factor at 10.6 μm wavelength. Combining both the CW electron beam and short pulse CO2 laser with super-cavity enhancement, 1  mW/2%  ?startb.w.end? flux and 30  kW/mm2/sr/2%  ?startb.w.end? brightness laser-Compton source is designed at 6.7-nm wavelength. The technological gap in the present component technologies are discussed, as well as any further required developments.
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Packaging of MEMS and MOEMS for harsh environments

Julian Kähler, Andrej Stranz, Andreas Waag, and Erwin Peiner

J. Micro/Nanolith. MEMS MOEMS 11, 021202 (May 07, 2012); http://dx.doi.org/10.1117/1.JMM.11.2.021202

Online Publication Date: May 07, 2012

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A method for die-attach based on sintering of micro- and nano-silver-particles, which is stable in harsh environments, was described. A modified flip-chip bonder providing high placement accuracy was used for precise pick and place die-attach. Components of sensors designed for data logging during deep drilling, i.e., a MEMS vibration sensor and a MOEMS pressure sensor, were assembled and tested at temperatures up to 250°C. Shear tests of bonded devices were performed before and after temperature load. Bonded silicon-on-insulator Wheatstone bridges and GaP-PD were tested by temperature cycling (50 cycles from 100°C up to 250°C).

Effect of added mass using resonant peak shifting technique

Rajesh Kumar Burra, Jyothi Vankara, and D. V. Rama Kota Reddy

J. Micro/Nanolith. MEMS MOEMS 11, 021203 (May 10, 2012); http://dx.doi.org/10.1117/1.JMM.11.2.021203

Online Publication Date: May 10, 2012

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Microcantilever is the fundamental structure for the realization of a microelectromechanical systems sensor with higher sensitivity and selectivity in a number of fields like biomedical, defense, and environmental. Present research is also focusing on the applications of microcantilever in the field of food industry. Among the two fundamental techniques for microcantilever, deflection and resonant peak shift, it was proven that the latter one is the best suited for added mass detection. In our study, we derive an analytical expression for δm based on the shift in frequency (δf') that accounts for the elasticity of the added mass and the location of the mass on the beam. In particular, we create a finite element methods model of our system in a commercial package, COMSOL (Bangalore, India), and carry out modal analysis for the cantilever beam resonator with and without the added mass, varying the relative stiffness and mass of the two components (the cantilever beam and the added mass), to compare the results of shift in resonant frequency with those obtained from rigid mass models. The results show the effect of elasticity clearly in certain ranges of relative stiffness and mass.

Reliability test methodology for MEMS and MOEMS under electrical overstress and electrostatic discharge stress

Sandeep Sangameswaran, Jeroen De Coster, Guido Groeseneken, and Ingrid De Wolf

J. Micro/Nanolith. MEMS MOEMS 11, 021204 (May 14, 2012); http://dx.doi.org/10.1117/1.JMM.11.2.021204

Online Publication Date: May 14, 2012

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We present an integrated reliability test methodology for electrostatic discharge (ESD) testing of micro-electromechanical systems (MEMS). It is shown that conventional ESD test methods for failure detection, like current and voltage waveforms during ESD stress and direct current leakage are insufficient for MEMS. A functionality-based approach using the mechanical response of the MEMS during ESD is needed to accurately and conclusively detect ESD failure in MEMS. A novel test setup with a probe-mountable human body model (HBM) tester is presented for this purpose. This setup can perform simultaneous measurements of MEMS out-of-plane displacement, HBM current and HBM voltage in the MEMS in situ during ESD stress. Using this setup, a few examples are demonstrated that show that traditional electrical characterization is overestimating the ESD robustness of MEMS devices. ESD testing of MEMS is performed at different pressures on RF MEMS actuators and show that more than one type of failure mechanism can occur due to ESD stress. ESD-induced charging and functionality degradation in RF MEMS actuators are also briefly discussed.

Parameter extraction of MEMS comb-drive near-resonance equivalent circuit: physically-based technique for a unique solution

Yasser Sabry, Mostafa Medhat, Bassam Saadany, Tarik Bourouina, and Diaa Khalil

J. Micro/Nanolith. MEMS MOEMS 11, 021205 (May 07, 2012); http://dx.doi.org/10.1117/1.JMM.11.2.021205

Online Publication Date: May 07, 2012

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A new extraction approach for MEMS comb-drive equivalent circuit parameters is presented. The proposed method eliminates the need for fitting and optimization by direct extraction from the measured data and, thus, avoids the nonuniqueness problem associated with fitting algorithms. A silicon-on-insulator-based MEMS comb-drive actuator is designed, fabricated, and measured, and its equivalent circuit is obtained by the proposed procedure. Analytical estimation for the uncertainty in the extracted values due to the discrete nature of the measurement frequency resolution is carried out. Uncertainty in the extracted values of the equivalent motional parameters is well below 0.6% when a 0.1-Hz frequency resolution is used. The method has been used to extract the resonator quality factor at both atmospheric and vacuum operations and can be extended to other types of resonators.

Frequency effects and life prediction of polysilicon microcantilever beams in bending fatigue

Jeng-Nan Hung and Hong Hocheng

J. Micro/Nanolith. MEMS MOEMS 11, 021206 (May 11, 2012); http://dx.doi.org/10.1117/1.JMM.11.2.021206

Online Publication Date: May 11, 2012

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Microcantilever beams have been widely used in micro-electromechanical systems (MEMS) devices. Their reliability is an essential factor for a successful MEMS product in an industrial setting. This study discusses the fatigue life of polysilicon microcantilever beams of various dimensions that were subjected to bending by a piezoelectric actuator. Both experimental and analytical results were obtained. A 100-Hz piezoelectric actuator was used to facilitate the test runs with good repeatability of the fatigue load. A finite element-modeling program, ANSYS, was used to investigate the stress distribution on the microcantilever beam. The fatigue life of the specimen was found to lie between 1.23×107 and 1.29×108 cycles for stress level ranges from 4.07 to 2.31 GPa. The experimental data from this study were incorporated with published references into an S-N curve, which showed that the fatigue life was dependent on both stress and frequency levels of the loading cycles. Low frequency loading was associated with increased sensitivity of fatigue life versus stress level. An empirical correlation was established for predicting fatigue to provide the MEMS designer with a reference for various applications.

Analytical design of polymer-encapsulated radio frequency microelectromechanical devices

Pejman Monajemi

J. Micro/Nanolith. MEMS MOEMS 11, 021207 (May 10, 2012); http://dx.doi.org/10.1117/1.JMM.11.2.021207

Online Publication Date: May 10, 2012

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An analytical design of radio frequency microelectromechanical (RF MEMS) devices and fabrication and encapsulation results is discussed. The encapsulated MEMS device is an in-plane variable capacitor (varactor), continuously tuned up to 115% at 3.25 V, showing a Q factor of 49 at 1 GHz at zero bias and self-resonance frequency above 5 GHz. The 60-μm-thick device measures 0.6  mm×0.6  mm and is fabricated using high-aspect ratio single-crystal and polysilicon technology, having an air gap of 0.8 μm for tuning and 2 μm for actuation. The effect of gap size, substrate doping, and gold coating on Q is studied. The wafer-level encapsulation is done by the thermal decomposition of a sacrificial polymer through a polymer overcoat at 130°C–150°C, followed by gold evaporation to provide a degree of hermeticity. The overcoat polymer is patterned instead of screen printed, which defines the package boundary, providing a small amount of interconnection. The encapsulated device measures 0.7  mm×0.7  mm, which is only 35% larger than the MEMS device. The insertion loss of the 1  μm/20  μm gold/Avatrel package is measured to be 1.4 dB at 1 GHz and 1.51 dB at 5 GHz, and the calculated nitrogen permeability is less than 1 Barrer. The temperature stability of the rest and the maximum capacitance is better than 7%, in the range of −30–50 °C.
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Conformal coating of poly-glycidyl methacrylate as lithographic polymer via initiated chemical vapor deposition

Shinya Yoshida, Tatsuya Kobayashi, Masafumi Kumano, and Masayoshi Esashi

J. Micro/Nanolith. MEMS MOEMS 11, 023001 (May 14, 2012); http://dx.doi.org/10.1117/1.JMM.11.2.023001

Online Publication Date: May 14, 2012

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This study reports on the investigation of the potential applicability of poly-glycidyl methacrylate (PGMA) films deposited via initiated chemical vapor deposition (i-CVD) as lithographic resists in the microfabrication of non-planar structures. We investigate the appropriate deposition conditions of i-CVD required to form PGMA films with smooth surfaces. As a result, under the optimal conditions determined by us, we fabricate films with nanometer-scale flat surfaces. Subsequently, we demonstrate that i-CVD is effective for conformally coating a high-aspect-ratio Si trench with PGMA film via our deposition experiments. In our deep-ultraviolet lithography experiment, we successfully fabricate a fine 20-μm line-and-space (L/S) pattern with a height of approximately 1  μm. Furthermore, in our electron-beam (EB) lithography experiment, we define a fine 350-nm L/S pattern with a height of 120 nm. In addition, the i-CVD process can be used to form highly-sensitive EB resist films; the lowest dose amount for patterning these films is evaluated to be less than 0.01  μC/cm2. Our results demonstrate that i-CVD is a potentially powerful method to conformally coat lithographic resist films on three-dimensional structures.

Homogeneous one-dimensional optical lattice generation using a digital micromirror device-based high-precision beam shaper

Jinyang Liang, Rudolph N. Kohn, Jr., Michael F. Becker, and Daniel J. Heinzen

J. Micro/Nanolith. MEMS MOEMS 11, 023002 (May 21, 2012); http://dx.doi.org/10.1117/1.JMM.11.2.023002

Online Publication Date: May 21, 2012

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A homogeneous one-dimensional optical lattice is demonstrated by using a high-precision beam shaper based on a digital micromirror device (DMD) with an imaging system containing a pinhole low-pass filter (LPF). This system is capable of producing a high-quality flattop beam profile to form a standing-wave optical lattice with a 50×50  μm2 flattop region. The periodic potential generated by the optical lattice confines ultracold atoms in Bose-Einstein condensate experiments. We conducted beam shaping tests at several wavelengths by implementing various coherent and incoherent light sources in the visible and infrared wavelength ranges. Experiments produced flattop and other well-controlled beam profiles with 0.2% to 0.26% root-mean-square (RMS) error after applying a digital LPF and nearly flat phase. Several concerns for the system design are presented. First, the energy requirement was determined by power conversion analysis and DMD diffraction efficiency simulation. In addition, a LabVIEW program was written to accelerate the speed of the iterative process for beam profile refinement. Finally, various camera calibrations improved the measurement accuracy. We achieved a 1.25% RMS error flattop beam with diameter of 70.4 μm at the atoms’ plane. Other beam profile measurements in different diagnostic planes demonstrated a good intensity uniformity of the optical lattice.
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