Gate oxide breakdown has always been a critical reliability issue in Complementary Metal-Oxide-Silicon (CMOS) devices. Pinhole analysis is one of the commonly use failure analysis (FA) technique to analysis Gate oxide breakdown issue. However, in order to have a better understanding of the root cause and mechanism, a defect physically without any damaged or chemical attacked is required by the customer and process/module departments. In other words, it is crucial to have Transmission Electron Microscopy (TEM) analysis at the exact Gate oxide breakdown point. This is because TEM analysis provides details of physical evidence and insights to the root cause of the gate oxide failures. It is challenging to locate the site for TEM analysis in cases when poly gate layout is of a complex structure rather than a single line. In this paper, we developed and demonstrated the use of cross-sectional Scanning Electron Microscope (XSEM) passive voltage contrast (PVC) to isolate the defective leaky Polysilicon (PC) Gate and subsequently prepared TEM lamella in a perpendicular direction from the post-XSEM PVC sample. This technique provides an alternative approach to identify defective leaky polysilicon Gate for subsequent TEM analysis.

In this paper, the effects of an open defect resulting in floating gate on combinational logic gate structures are studied. From this study, a novel method is derived to predict and narrow down the potential open defect location from a long failure path that is driving multiple branches of input nodes, into a much smaller segment without EBAC analysis. This method is applied with great success to localize open defects on actual low yield cases from advanced technology nodes with significant reduction in FA cycle time.

This paper describes the debug and analysis process of a challenging case study from wafer foundry which involved a circular patch functional leakage failure that was induced from device parametric drift due to thicker gate oxide with no detection signal from inline monitoring vehicles. It highlights the need for failure analyst to always be inquisitive and to deep dive into the failure symptoms to value-add the fab in discovering the root cause of the failure in challenging situation where information is limited.

This paper describes the observation of photoemissions from saturated transistors along a connecting path with open defect in the logic array. By exploiting this characteristic phenomenon to distinguish open related issues, we described with 2 case studies using Photon Emission Microscopy, CAD navigation and layout tracing to identify the ‘open’ failure path. Further layout and EBAC analysis are then employed to effectively localize the failure site.

This paper describes 2 case studies where device characterizations using Atomic Force Probe (AFP) nanoprobing, allow for the localization and verification of design weakness and process variations on the Analog-to-Digital (ADC) block that resulted in degraded device performance and severe yield loss. In these cases, the sensitive resistor structures in the ADC block was impacted due to design pattern density interaction with process fabrication steps. In addition, close collaboration with customer was also essential for quick root cause identification, design and process fix.