This paper illustrated the beauty of AFP nanoprobing as the critical failure analysis tool in resolving the one-time programmable (OTP) non-volatile memory data retention failures through electrical simulation in wafer fabrication. Layout analysis, electrical simulation using Meilke’s method, UV erase methodology (to differentiate between mobile ion Meilke’s method contamination and charge trap centers) and a few other FA approaches were employed to determine the different root causes in the three OTP failure case detailed in this paper.. These include SiN trap center issue, poly stringers and abnormal layer at the initial CESL (Contact etch stop layer) nitride. This paper placed a strong emphasis on systematic problem solving approach, deep dive and use of right FA approach/tool that are essentially critical to FA analysts in wafer foundry since there is always minimal available data provided. It would serve as a good reference to wafer Fab that encountered such issue.

In this work, we present TEM failure analysis of two typical failure cases related to metal voiding in Cu BEOL processes. To understand the root cause behind the Cu void formation, we performed detailed TEM failure analysis for the phase and microstructure characterization by various TEM techniques such as EDX, EELS mapping and electron diffraction analysis. In the failure case study I, the Cu void formation was found to be due to the oxidation of the Cu seed layer which led to the incomplete Cu plating and thus voiding at the via bottom. While in failure case study II, the voiding at Cu metal surface was related to Cu CMP process drift and surface oxidation of Cu metal at alkaline condition during the final CMP process.

This paper places a strong emphasis on the importance of applying Systematic Problem Solving approach and use of appropriate FA methods and tools to understand the “real” failure root cause. A case of wafer center cluster RAM fail due to systematic missing Cu was studied. It was through a strong “inquisitive” mindset coupled with deep dive problem solving that lead to uncover the actual root cause of large Cu voids. The missing Cu was due to large Cu void induced by galvanic effects from the faster removal rate during Cu CMP and subsequently resulted in missing Cu. This highlights that the FA analyst’s mission is not simply to find defects but also play a catalyst role in root cause/failure mechanism understanding by providing supporting FA evidence (electrically/ physically) to Fab.

This paper illustrated the beauty of AFP nano-probing as the critical failure analysis tool in localizing new product design weakness. A 40nm case of HTOL Pin Leakage due to Source/Drain punch-through at a systematic location was discussed. The root cause and mechanism was due to VDS overdrive testing issue. This paper placed a strong emphasis on systematic problem solving approach, deep dive and use of right FA approach/tool that are essentially critical to FA analysts in wafer foundry since there is always minimal available data provided. It would serve as a good reference to wafer Fab that encountered such issue.

High gate to source/drain (S/D) leakage was observed at both failed pins and ET structures with random failure signatures. Detailed TEM failure analysis revealed an abnormal thin Nitrogen-rich nitride layer along the poly gate which extended to the S/D regions. Along the abnormal nitride layer, appreciable Arsenic (As) segregation occurred. The segregated As dopants at these interfaces may form a continuous conducting path, accounting for the gate to S/D leakage mechanism. The preferable As segregation at the Silicon nitride interface may be related to a vacancy-assisted As diffusion process.

This paper described a gate oxide failure case which affected the electrical parameters such as Vt and Idsat of both HV N&P MOS. A systematic problem solving approach combined with several FA techniques was applied to find the root-cause to be arsenic outgas cross-contamination.