Abstract This paper presents a method for determining positional variation and offsets in high aspect ratio etches used in the production of 3D NAND devices. The method uses a 3D fiducial as a positional reference in the field-of-view, which not only allows for high precision tracking of features through the depth of the device, but also aids in the alignment of images when performing 3D reconstructions. The workflow is based on plasma dual beam diagonal milling, which allows users to characterize structures through the device stack at a much higher throughput/slice than conventional methods, enabling enhanced process monitoring and control.

Abstract A failure analysis work flow is presented demonstrating dislocation visualization, site isolation, TEM lamella preparation and defect characterization. A novel beam control technique allows visualizing dislocations with significantly improved spatial resolution in SEM using Electron Channeling Contrast Imaging. Site-specific TEM preparation on dislocations is therefore possible. The prepared thin lamella can be inspected in the SEM using STEM to study dislocations. This is a cost effective work flow without using TEM.

Abstract This paper presents a novel approach for detecting channel hole bending (ChB) defects in vertical NAND flash memory. Such defects are the result of etching process inconsistencies and contribute to data loss and device failure by inducing leakage current between adjacent channel holes. In order to satisfy long-term reliability requirements and volume demand, chipmakers must be able to detect these defects prior to shipping during electrical die sorting and screening procedures. The proposed method works by monitoring leakage current differences between diagonally and horizontally adjacent memory cells and is shown to be an effective screening technique.

Abstract With high implant doses, strained silicon technologies and shrinking feature sizes, dislocation related failures seem to gain more importance in advanced CMOS devices. On the basis of case studies, different types of dislocations as well as the electrical characteristics of the corresponding devices will be presented.

Abstract This paper describes the development and implementation of a TEM-based measurement procedure and shows how it is used to determine the verticality or etching angle of channel holes in V-NAND flash with more than 200 layers of memory cells. Despite the high aspect ratio of the region of interest, the method can resolve offsets down to a few nm. Such precision is critical, as the paper explains, because the radius and thus electrical characteristics of each memory cell is determined by the etching angle.

Abstract The presence of crystalline defects, including dislocations and pipeline defect, is detrimental to both the processing and the intrinsic quality of semiconductor devices. The electrical parametric or functional failures generated by those defects require accurate identification and proper classification in a continuous improvement mindset. Depending on the failure analyst choice of the investigation technique, the distinction between a dislocation and a pipeline defect can be difficult. In this paper, based on case studies of mixed-mode devices, the various electrical and physical FA investigation techniques are explored and compared. From an electrical investigation standpoint, fault localization techniques will be reviewed (Thermal Laser Stimulation and Photon Emission Microscopy) as well as the direct electrical measurements means (external measurement and nanoprobing AFP). From a physical analysis standpoint, the use of various methods after deprocessing will be considered: top down delineation etch, Atomic Force Microscopy (AFM), Scanning Microwave Microscopy (SMM), and Transmission Electron Microscopy (TEM). The position of the defect as well as its physical signature observed through the various methods will determine its proper classification and will determine the appropriate corrective actions. The paper will be concluded with a discussion on the physical differences between a dislocation and a pipeline defect, as well as insights into the wafer fab manufacturing process.

Abstract The cross-sectional and planar analysis of current generation 3D device structures can be analyzed using a single Focused Ion Beam (FIB) mill. This is achieved using a diagonal milling technique that exposes a multilayer planar surface as well as the cross-section. this provides image data allowing for an efficient method to monitor the fabrication process and find device design errors. This process saves tremendous sample-to-data time, decreasing it from days to hours while still providing precise defect and structure data.

Abstract As semiconductor devices continue to shrink, novel materials (e.g. (Si)Ge, III/V) are being tested and incorporated to boost device performance. Such materials are difficult to grow on Si wafers without forming crystalline defects due to lattice mismatch. Such defects can decrease or compromise device performance. For this reason, non-destructive, high throughput and reliable analytical techniques are required. In this paper Electron Channeling Contrast Imaging (ECCI), large area mapping and defect detection using deep learning are combined in an analytical workflow for the characterization of the defectivity of “beyond Silicon” materials. Such a workflow addresses the requirements for large areas 10 -4 cm 2 with defect density down to 10 4 cm -2 .

Abstract Bond pad characterization is usually performed by mechanical cross-sectioning as well as pull and shear tests. However, since all these methods apply mechanical forces to the bond pad, artifacts may result. Focused Ion Beam (FIB) characterization is a mechanically stress-free characterization method, which allows more accurate conclusions regarding the intermetallic behaviour of the bonding area. Some new approaches presented here show how to improve the FIB characterization procedure and to combine it with classical characterization methods.

Abstract This paper describes the application of 3D FIB-SEM tomography as a method for quantifying process variations across the die and across the wafer, as well as layout investigations. In this study, the analysis of results acquired by 3D FIB-SEM tomography were applied to a 64L 3D-NAND device where process induced variation in the high aspect ratio vertical memory channels is measured and to a double stack 3D-NAND architecture, which is comprised of two 32-layer stacks where eccentricity of the pillars was evaluated for layers in both upper and lower stacks. In addition, a partial layout of a 14nm logic device is investigated by this method, demonstrating the capabilities for structural verification, and structural overlay of elements from a 7nm logic device were also evaluated. The results demonstrate the value of 3D FIB-SEM tomography for physical confirmation of the structural layout, which can be applied towards device debug and reverse engineering.

Abstract This paper evaluates the use of nanomilling and STEM imaging to analyze failure mechanisms in sub-50 nm InP HEMTS. The devices were life tested at elevated temperatures and biases and their electrical characteristics were measured at each stress interval. Devices that were damaged were investigated further to assess the underlying failure mechanism. Advanced microscopy with sub-nm resolution was employed to examine the physical characteristics of the failed HEMT devices at the atomic scale. As the paper explains, the examination was conducted using a focused ion beam/scanning electron microscope (FIB/SEM), an Ar gas ion nanomill, and STEM imaging.

Abstract By combining transmission electron microscopy (TEM) [1] with scanning capacitance microscopy (SCM) [2], it is possible to enhance our understanding of device failures. At Sandia, these complementary techniques have been utilized for failure analysis in new product development, process validation, and yield enhancement, providing unique information that cannot be obtained with other analytical tools. We have previously used these instruments to identify the root causes of several yield-limiting defects in CMOS device product lines [3]. In this paper, we describe in detail the use of these techniques to identify electrically active silicon dislocations in failed SRAMs and to study the underlying leakage mechanisms associated with these defects.

Abstract The aggressive scaling of metal oxide semiconductor field effect transistor (MOSFET) device features, including gate dielectrics, silicides, and strained Si channels, presents unique metrology and characterization challenges to control electrical properties such as reliability and leakage current. This paper describes challenges faced in measuring the thickness of thin gate oxides and interfacial layers found in high-K gate dielectrics, determining Ni silicide phase in devices, and characterizing strain in MOSFETs with SiGe stressors. From case studies, it has been observed that thin layers (gate oxide, high-K film thickness, and interfacial layer) can be measured using high-resolution transmission electron microscopy (HRTEM) with good accuracy but there are some challenges in the form of sample thickness, damage-free samples, and precise sectioning of the sample for site-specific specimens. Complementary information based on HRTEM, annular dark field, and image simulation should be used to check the accuracy of thin gate dielectric measurements.

Abstract Light emission and heat generation of Si devices have become important in understanding physical phenomena in device degradation and breakdown mechanisms. This paper correlates the photon emission with the temperature distribution of a short channel nMOSFET. Investigations have been carried out to localize and characterize the hot spots using a spectroscopic photon emission microscope and a scanning thermal microscope. Frontside investigations have been carried out and are compared and discussed with backside investigations. A method has been developed to register the backside thermal image with the backside illuminated image.

Abstract It is becoming more important to observe structures and failed sites in LSIs. An atomic force microscope (AFM) can obtain atomic scale topographic images on sample surfaces. To analyze failures in LSIs, several treatments for the AFM observation, such as wet etching and mechanical polishing for a crosssectional imaging, have been proposed so far. A good correlation of AFM images using FIB anisotropic etch with those acquired by conventional technique such as SIM and TEM has been demonstrated A crystallographic information about Al thin film is obtained by AFM using this technique.

Abstract This presentation addresses topics of relevance to scanning electron microscopy, including SEM basics, electron guns, electron optics, beam-specimen interactions, signal detection, sample prep and cleanliness, low-voltage imaging, nonconductive imaging, voltage contrast, stage biasing, electron channeling contrast imaging, magnetic contrast imaging, STEM-in-SEM, 3D imaging and analytics, and image post-processing.

Abstract In accordance with the predictions of the International Semiconductor Association, a further decrease in the structural widths of semiconductor devices is expected. For an in-depth characterization of actual structural details, the transmission electron microscopy (TEM)-technique is becoming more and more significant. An urgent requirement is in the visualization of dimensions of the doped regions and estimation of p-n-junctions profile with a high level spatial resolution. The off-axis electron holography, a special TEM-technique, is able to visualize electrically active areas in semiconductors. This article describes a way to achieve sample preparation for TEM-holography from actual memory products and also provides an idea of the potential of this technique for semiconductor failure analysis. It shows that different types and sizes of FET's and testing structures could be visualized by focusing on the physical basics, technical solutions, and sample preparation.

Abstract An advanced technique for site-specific Atom Probe Tomography (APT) is presented. An APT sample is prepared from a targeted semiconductor device (commercially available product based on 14nm finFET technology). Using orthogonal views of the sample in STEM while FIB milling, a viable APT sample is created with the tip of the sample positioned over the lightly-doped drain (LDD) region of a pre-defined PFET. The resulting APT sample has optimal geometry and minimal amorphization damage.

Abstract A technique for preparation of a pillar shaped sample and its multi-directional observation of the sample using a focused ion beam (FIB) / scanning transmission electron microscopy (STEM) system has been developed. The system employs an FIB/STEM compatible sample rotation holder with a specially designed rotation mechanism, which allows the sample to be rotated 360 degrees [1-3]. This technique was used for the three dimensional (3D) elemental mapping of a contact plug of a Si device in 90 nm technology. A specimen containing a contact plug was shaped to a pillar sample with a cross section of 200 nm x 200 nm and a 5 um length. Elemental analysis was performed with a 200 kV HD-2300 STEM equipped with the EDAX genesis Energy dispersive X-ray spectroscopy (EDX) system. Spectrum imaging combined with multivariate statistical analysis (MSA) [4, 5] was used to enhance the weak X-ray signals of the doped area, which contain a low concentration of As-K. The distributions of elements, especially the dopant As, were successfully enhanced by MSA. The elemental maps were reconstructed from the maps.

Abstract Failure analysis of electronic components is almost always destructive, and there’s no going back once a destructive step is performed. Or, that’s the way it used to be, before the development of some of the more sophisticated nondestructive techniques such as computed tomography (CT). This paper presents a case study of an optocoupler, the suspected failure of which could not be confirmed until the last day of the month-long analysis, when the cause of failure was conclusively determined by a CT model captured weeks earlier.