Dongxian Li†
abc,
Tao Zhang†a,
Weisheng Yuea,
Ping Gaoa,
Yunfei Luoa,
Changtao Wanga and
Xiangang Luo*ac
aState Key Laboratory of Optical Technologies on Nano-Fabrication and Micro-Engineering, Institute of Optics and Electronics, Chinese Academy of Sciences, P.O. Box 350, Chengdu 610209, China. E-mail: lxg@ioe.ac.cn
bSchool of Optoelectronic Science and Engineering, University of Electronic Science and Technology of China, P.O. Box 350, Chengdu 610209, China
cSchool of Optoelectronics, University of Chinese Academy of Sciences, Beijing 100049, China
First published on 22nd November 2022
Particle contamination of photo masks is a significant issue facing the micro-nanofabrication process. It is necessary to analyze the particulate matter so that the contamination can be effectively controlled and eliminated. In this study, Raman spectroscopy was used in combination with scanning electron microscopy with energy analysis (SEM-EDX) techniques to study the contamination of individual particles on the photomask. From Raman spectroscopic analysis, the Raman bands of particles mainly contributed to the vibrational modes of the elements C, H, O, and N. Their morphology and elemental composition were determined by SEM-EDX. The sizes of the particles are mostly less than 0.8 μm according to the SEM image analysis. Hierarchical clustering analysis (HCA) of the Raman spectra of particles have shown that the particles can be classified into six clusters which are assigned to CaCO3, hydrocarbon and hydrocarbon polymers, mixture of NH4NO3 and few (NH4)2SO4, mixtures metal oxides, D and G peaks of carbon, fluorescent and (NH4)2SO4 clusters. Finally, principal component analysis (PCA) was used to verify the correctness of the classification results. The identification and classification analysis of individual particles of photomask contamination illustrate the chemical components of the particles and provide insights into mask cleaning and how to effectively avoid particle contamination.
Chemical compositions of particles on the surface of the photomasks are mostly analyzed using chemical analysis methods, such as thermal desorption gas chromatography–mass spectrometry (TD-GC/MS).4,5 The chemical analyzing methods require complex and time-consuming sample pre-treatment, which may cause damage to the fine patterns of the photomasks. Other methods, such as Auger electron spectroscopy (AES),6 Fourier transform infrared spectroscopy (FTIR),7 time-of-flight secondary ion mass spectrometry (TOF-SIMS),8–10 X-ray photoemission spectroscopy (XPS),11 and energy dispersive X-ray spectroscopy (EDX)12 have been reported to analyze particle contaminants of photomasks. The studies have found that the particulate contamination components are mainly ammonium sulphate salts13 from cleaning chemicals and hydrocarbons10 formed by pollutant exhaust. However, there are some limitations of these methods. The AES, XPS and EDX are performed in a vacuum environment, which limits the size of the mask plate. In addition, the efficiency is low. The FTIR has relatively low sensitivity and it is difficult to analyze particles small than 2 μm due to the large spot size. The TOF-SIMS need to gasify the particles, which may cause damage to mask patterns.
The chemical analyses of contamination particles are mostly bulk analyses, with which many particles are analyzed as a whole. The chemical composition can be obtained at one time in the bulk analysis and the analysis is fast. However, some particles may have some elements lower than detection limit of the bulk analysis and the elemental information may be lost in the bulk analysis. In addition, it is difficult to identify the source of each particle with the bulk analysis. Individual-particle analysis can partly overcome the limitations of bulk analysis. In the past years, individual-particle analysis has been proven to be a useful technique to analyze the physical and chemical properties of aerosol particles to identify the sources of pollution.14–16 Although individual-particle analysis has some advantages over bulk analysis in particle studies, it requires the analyzing instrument to be able to discriminate each particle and then analyze it. EDX, single particle laser spectroscopy, focused proton beam and focused X-ray beam have been used to obtain chemical compositions of individual particles.14,17,18
Raman spectroscopy has received a great deal of attention from all walks of life since its discovery in 1928. The Raman effect has led to an in-depth study of the structure of molecules by spectroscopy, hence the name “fingerprint spectroscopy”, which is specific, fast, sensitive and non-destructive.19–21 Raman shift corresponds to the vibration or rotation mode of the corresponding chemical bond, which can realize the detection and identification of the small particle.22–25 It is therefore of great advantage in the analysis of the structure of compounds. E. M. Malykhin et al. investigated the structure and chemical properties of carbon films under 13.5 nm UV irradiation using Raman and IR spectroscopy, respectively.26 It was found that the deposited carbon films were amorphous carbon based on sp2 carbon, and the mechanism of the formation of this amorphous carbon was briefly described, providing important theoretical support for the subsequent cleaning method. T. Horiuchi et al. detected by Raman that the particulate contamination on the surface consisted mainly of (NH4)2SO4.6 R. J. Naber and K. Saga et al. used Raman spectroscopy for the detection and analysis of asymptotic mask contamination particles.9 The main Raman feature peaks detected included 980–1000 cm−1 (SO4+), 3000–3600 cm−1 (NH4+) and 2800–2900 cm−1 (C–H), while the S–O and N–H bonds were not detected due to the small size of the particles. These studies all demonstrate the enormous potential of Raman to detect particle contamination of masks. In the Raman spectroscopy analysis, the exciting laser beam is highly focused on a small pot of less than 1 μm. The particles of photomasks can be analyzed individually.
In this work, we performed a comprehensive study of particle contaminants on the surface of photomasks by a combination of Raman spectroscopy with SEM-EDX. The individual-particle analysis method is used to discriminate each particle. Raman spectroscopy and EDX readily detect chemical compositions, while SEM readily analyses microscopic morphologies of the particles. The measured spectra of individual particles are analyzed with cluster analysis (HCA and PCA). Cluster analysis is a classification method that integrates disorganized data into several classes based on the correlation or dissimilarity between the classes. According to the cluster analysis, the sources of the particles on the photomasks can be analyzed. To our knowledge, there are very few systematic studies for the detection on the chemical components of mask contamination particles in the literature. This study will help to understand the chemical components of photomask pollution, so as to predict the source of pollution and take effective measures.
Fig. 1 Dark field image of a photomask (a) and schematic of measurement of contaminated particles with Raman spectroscopy (b). |
The photomasks were used for direct measurements of the particles with Raman spectroscopy. A total of 200 sample particles were collected in this study. Before doing the Raman spectroscopy measurements, the contaminated particles were detected and position marked with a dark field microscope (Fig. 1(b)). The Raman spectra were obtained using a Horiba LabRaman HR Evolution confocal Raman microscopy system (HORIBA JOBIN YVON, France) equipped with a 532 nm laser and 100–4000 cm−1 in the spectral range. The laser with a spot size of 0.7 μm is focused onto the surface of the particle sample using a 100× objective lens. The acquisition time was set to no exceed 5 s to avoid burning of the particles. The system is calibrated to a silicon substrate standard of 520 cm−1 prior to measurement of particles. Raman spectral data of individual particles were collected randomly over the surface of the photomask.
The morphology and elemental composition of the position-marked particles were characterized by SEM equipped with EDX (Hitachi SU800). The SEM can analyze the morphology of particles down to the nanometer level. The EDX can provide information on the chemical elements of particles with the excitation of characteristic X-ray spectrum of elements by the energy electron beam.
Category | Raman shift (cm−1) | Assignment | Ref. |
---|---|---|---|
a | 149 | Ti–O | 33 and 34 |
276 | O–O | ||
702 | CO | ||
1079 | C–O | ||
b | 441 | S–O/SO | 35 |
610 | S–O/SO | ||
970 | S–O/SO | ||
c | 460 | Si–O | 35 |
753 | O–C–O | ||
973 | S–O/SO | ||
1046 | N–O | ||
1482 | C–O | ||
2956∼3040 | C–H (asymmetric CH3 stretch, helical and non-helical conformation) | ||
d | 1045 | N–O | 36 |
1296 | CH2 (CH2 twist, trans-conformers) | ||
1447 | C–O | ||
2889 | CH3 (symmetric CH3 stretch, helical and non-helical conformation) |
EDX measurements of the particles were performed as a complementary way to understand the chemical compositions. The EDX has advantage to analyze inorganic components. A typical Raman spectrum and corresponding EDX elemental analysis of two particles was shown in Fig. 3. From these, it was clearly found that a represented a calcium salt particle and b represented a carbon containing particle. We simply divided all particles into two main categories of elements based on this. One class of particles mainly contained Si, O, Cr, and Fe. The mask is prepared by coating a quartz substrate with a chromium film before forming the lithographic pattern, so it maybe comes from the mask. Another class of particles contained mainly Ca, Na, C, S, O and some other minor elements. Photolithography is exposed under vacuum conditions and the reaction of various component materials (photoresists, micro sensors, etc.) during the exposure process will release some volatile gases, the common gas components are mainly NH3, CO2, SO2 and some organic volatile gases (e.g. acetone). Calcium is chemically active and can form a layer of oxide (calcium oxide) or a film of nitride (calcium nitride) on its surface in the air. These components adhere to the surface of optical components and break under the energy of laser, reacting with water vapour to form carbon deposits and oxide particles, resulting in a reduction in reflectance, transmittance and throughput of optical components, affecting the printing performance of mask patterns and chip preparation. The third class of particles contained very few identified elements, such as Ti. The origins of these particles were not clear. In addition, there may be some light elements that were not detected due to the detection limit of the EDX.
Fig. 3 A typical Raman spectrum (a(1) and b(1)) and corresponding EDX (a(2) and b(2)) elemental analysis of two particles. |
By analyzing the individual particles using SEM-EDX, these contamination particles were observed and identified based on their morphologies and elemental composition. A preliminary guess is that it contains a composition of calcium carbonate, ammonium sulphate, silica and other components.
Particle morphology was analyzed qualitatively by Image-J software to study the size of the particles. We use equivalent diameter (Dequ) to estimate the size of the irregular particles. In the calculation, the size of the particles is calculated as the diameter of a spherical particle with the same area. The calculation is using the equation:37
70 particles were measured for the size. The number-size distribution of individual particles in the masks measured from the SEM images is shown in Fig. 5. It showed that the measured particles are mainly in a diameter range of less than 0.8 μm. The largest proportion of the size distribution is smaller than 2 μm, which meant that a large number of particles exist in small sizes, mostly at the micron level or even the nano level. B. J. Grenon et al. reported particles of about 0.5 μm in size.31 R. M. Silver et al. detected particles with a size of 1 μm.32 W. Staud et al. observed nucleation particles smaller than 5 μm and elongated particles larger than 10 μm.38 B. J. Grenon et al. discovered a large growth of 10 μm sized particles on the mask.30 R. J. Naber et al. prepared and analyzed defective particles of 0.5 μm.9 T. Horiuchi et al. characterised and analysed the haze particles for 1 μm × 0.3 μm and 0.1 μm × 0.1 μm.6 However, for the sub-resolution size of 40 nm on the mask (corresponding to 22 nm nodes and below), the allowable particle size is 18 nm.39 Therefore, detection techniques for smaller nodes need to be further developed.
The 200 particles samples were divided into 6 main clusters, with 10% of the first category, 8% of the second, 26% of the third, 17% of the fourth, 24% of the fifth and 15% of the sixth. The Raman spectral characteristic peaks and assignments analysis are in Table 2.
Cluster | Component | Raman shift (cm−1) | Ref. |
---|---|---|---|
1 | CaCO3 | 153, 281, 713, 1085, 1437, 1749, 2885 | 33 and 40 |
2 | Hydrocarbon and hydrocarbon polymers | 1081, 1300, 1443, 2885 | 36 |
3 | Mixture of NH4NO3 and few (NH4)2SO4 | 138, 462, 541, 757, 937, 1043, 1472, 2959, 3039 | 35 |
4 | Mixtures metal oxides | 217, 284, 397, 541, 1010, 1086, 1288 | 41 and 42 |
5 | D and G peaks of carbon and fluorescent | 1346, 1588 | 43 |
6 | (NH4)2SO4 | 441, 611, 973, ∼3124 | 35 |
The first cluster was mainly calcium carbonate (CaCO3) and mostly circular in shape. In this cluster of the Raman spectra of CaCO3, the Raman shifts were attributed to 153 cm−1, 281 cm−1, 713 cm−1 and 1085 cm−1, 1437 cm−1, and 1749 cm−1. The C–O vibrations of the internal carbonate group at room temperature and pressure were mainly two lattice vibrations at 153 cm−1 of advection and at 281 cm−1 of oscillation, in-plane bending vibrations at 713 cm−1, symmetric stretching vibrations at 1085 cm−1, antisymmetric stretching vibrations at 1437 cm−1 and out-of-plane bending vibrations at 1749 cm−1. 33,40 The second cluster was mainly hydrocarbon and mainly the vibration peak of the C–C bond and C–H bond. This Raman shift were attributed to 1081 cm−1, 1300 cm−1, 1443 cm−1 and 2885 cm−1. These Raman shifts were attributed to the vibration of the C–C stretch, CH2 twist, CH2 bend + asymmetric CH3 bend and asymmetric CH2 stretch, respectively. In addition these mixtures also contained hydrocarbon polymers.36 The third cluster was mainly a mixture of ammonium nitrate (NH4NO3). Mixtures Raman shifts were attributed to 138 cm−1, 462 cm−1, 541 cm−1, 757 cm−1, 937 cm−1, 1043 cm−1, 1472 cm−1, 2959 cm−1 and 3039 cm−1. 1043 cm−1 was attributed to the vibration of the N–O bond of nitrate. The remaining Raman shift was attributed to a mixture of NH4NO3 and a few ammonium sulphates ((NH4)2SO4).35 The fourth cluster was mainly mixtures of metal oxides. The Raman shifts were attributed to 217 cm−1, 284 cm−1, 397 cm−1, 541 cm−1, 1010 cm−1, 1086 cm−1and 1288 cm−1. Mixtures of metal oxides mainly included iron oxide (FeO, Fe3O4, Fe(OH)2 and Fe2O3) and chromium oxides (Cr2O3).41,42 The fifth cluster category was mainly the D and G peaks of carbon and fluorescent. Of these, 1346 cm−1 and 1588 cm−1 belonged to the D and G peaks of carbon, respectively.43 This type of contamination may be caused by soot in the air environment during transport or storage transfer. Fluorescent had no very distinctive characteristic Raman shift and the Raman peak was almost swamped by the fluorescence signal. This is one of the disadvantages of Raman detection. The sixth cluster was mainly ammonium sulphate ((NH4)2SO4). The Raman shifts of (NH4)2SO4 were attributed to 441 cm−1, 611 cm−1, 973 cm−1 and 3124 cm−1. The Raman shifts of 441 cm−1, 611 cm−1 and 973 cm−1 were mainly from vibrations of SO4+, and ∼3124 cm−1 was from broad overlap peak of NH4−.35
According to the hierarchical cluster results, three of the particle samples were misclassified as cluster 3, three particles were misclassified as cluster 4 and five particles were misclassified as cluster 5. It was possible that some of the particles were so small that only one characteristic peak appeared and the others were not evident and therefore classified as other. Additionally, some particles had low peak Raman feature intensities and fluorescent signals so strong that the Raman signal is ignored and classified as fluorescent. After calculation, the sensitivity of the complete data set classification was 94.5%.
The Raman spectra of the measured particles were compared with Raman spectra database KnowItAll that is built in LabSpec6 software. The chemical components such as calcium carbonate and ammonium sulphate were identified as the main types of particles by the comparisons, which were consistent with classification. However, due to the complexity of particulate matter and limitation of the database, and there are some particles unidentified.
Hierarchical cluster analysis is suitable for simple data scenarios and is more complex to calculate for larger data volumes. For the accuracy of the classification, principal component analysis (PCA) was also selected for validation. PCA allows the projection of high-dimensional data onto a two- or three-dimensional plane. For the 200 particles of high-dimensional Raman data in this paper, the PCA method can be effectively used for dimensionality reduction analysis.
The full Raman spectrum was first processed to baseline subtraction and normalization. Then, the covariance matrix was selected for PCA calculation. Fig. 7(a) illustrated the calculation results of eigenvalue of all the PCs. Based on these results, the Raman spectrum information of the above particle samples were extracted three principal components, and the total contribution rate can reach 89.2%. The contribution rates of PC1, PC2 and PC3 are 74.6%, 9.5% and 5.2%, which means the extracted three principal components can represent the whole Raman spectrum information. At this point 200 Raman spectra were extracted into 3 PCs, a significant reduction in workload.
A scatter plot of the classification results was shown in Fig. 7(b). One of the dots represented the Raman spectrum of a particle. Most importantly, the above six clusters of particle samples can be distinguished after the PCA. The first and second clusters are similar because they have relatively similar Raman characteristic peaks. Therefore, the two common unsupervised recognition methods are suitable for contaminate particles information on the data in this study.
The identification and classification of the particles types help to take measures to control and remove particles more effectively in laboratories and industries. For the particle control, we need to reduce the particles from environment, operations and machines. For the removal of the contamination, some particles such as calcium carbonate and ammonium sulphate can be removed by conventional semiconductor cleaning process. For some secondary particles that are caused by photochemical reaction in the UV exposure process, adding inert gases in the exposure process may help to reduce the formation. For other particles, the removal need to according to the chemical composition.
Footnote |
† Dongxian Li and Tao Zhang contributed equally to this paper. |
This journal is © The Royal Society of Chemistry 2022 |