In this work, we present two different approaches to pattern Ru metal lines at a metal pitch of 18 nm, by making use of self-aligned double patterning (SADP) in combination with EUV lithography. The first and more conventional patterning approach is to define the 18 nm pitch gratings into a hard mask by means of SADP, which is consequently transferred into the Ru layer by means of direct metal etch. The second and more innovative approach consists of a combination of direct metal etch and damascene filling of Ru. This so-called mixed flow is a patterning-friendly approach which enables the integration of self-aligned cuts and vias. We will share the schematics as well as the results for 18 nm pitch Ru gratings on 300 mm Si wafers for both approaches. Finally, we will discuss and demonstrate the enablement of selfaligned cuts and vias for the mixed flow, which makes this patterning flow a promising alternative to standard damascene patterning for future interconnects at sub-20 nm metal pitches.
For many years traditional 193i lithography has been extended to the next technology node by means of multi-patterning techniques. However recently such a 193i technology became challenging and expensive to push beyond the technology node for complex features that can be tackled in a simpler manner by the Extreme UltraViolet Lithography (EUVL) technology. Nowadays, EUVL is part of the high-volume manufacturing device landscape and it has reached a critical decision point where one can push further the single print on 0.33NA full field scanner or move to a EUV double patterning technology with more relaxed pitches to overcome current 0.33NA stochastic limits. In this work we have selected the 28nm pitch dense line-space (P28) as critical decision check point. We have looked at the 0.33NA EUV single print because it is more cost effective than 0.33NA EUV double patterning. In addition, we have conducted a process feasibility study as P28 in single print is close to the resolution limit of the 0.33NA EUV full field scanner. We present the process results on 28nm dense line-space patterning by using Inpria’s metal-oxide (MOx) EUV resist. We discuss the lithographic and etching process challenges by looking at resist sensitivity, unbiased line edge roughness (LER) and nano patterning failures after etching (AE), using broad band plasma (BBP) and e-beam (EB) defectivity inspection tools. To get further understanding on the P28 single patterning capability we have integrated the developed EUV MOx process in a relevant iN7 technology test vehicle by developing a full P28 metallization module with ruthenium. In such a way we were able to carry on electrical tests on metallized serpentine, fork-fork and tip-to-tip structures designed with a purpose of enabling further learning on pattern failures through electrical measurements. Finally, we conclude by showing the readiness of P28 single exposure using Inpria’s MOx process on a 0.33NA EUV full field scanner.
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