LPP EUV Source Development and HVM I Productization
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1 LPP EUV Source Development and HVM I Productization October 19, 2009 David C. Brandt*, Igor V. Fomenkov, Alex I. Ershov, William N. Partlo, David W. Myers Richard L. Sandstrom, Norbert R. Böwering, Alexander N. Bykanov, Georgiy O. Vaschenko Oleh V. Khodykin, Shailendra N. Srivastava, Imtiaz Ahmad, Chirag Rajyaguru Daniel J. Golich, Silvia De Dea, Richard R. Hou, Kevin O Brian, Wayne J. Dunsten
2 Contents Introduction to EUV LPP Product EUV Power and Dose Stability Debris Mitigation Droplet Generator 5sr Normal Incidence Collector Intermediate Focus Protection Cost of Operation HVM I Source Production Roadmap and Summary Acknowledgements 2
3 Introduction
4 Laser Produced Plasma Source Architecture (in vacuum, all reflective optics) Droplet Generator Source Chamber BTS Beam Transport System and Focusing IF Protection Collector 3 Stage CO 2 Laser Isolator Isolator 4
5 First LPP Source Completed Test and was Shipped to ASML LPP source vessel as installed at Cymer (left) Crated source vessel leaving Cymer (top) 5
6 First Source is Installed and Operational Droplet generation (30μm diameter) and laser targeting confirmed Control system is operational The source vessel is fully populated with all devices and sensors (functionality confirmed) Operational status is confirmed Performance optimization is in process 6
7 Laser Produced Plasma Performance Status Performance Current HVM I Target EUV power at Intermediate Focus 70W 100W CO 2 laser power and beam quality >10kW M 2 ~1.4 >10kW M 2 ~1.2 Dose stability during closed loop operation <±0.35% <±0.30% Debris mitigation effectiveness validation 5sr 5sr (full lifetime testing pending) Burst duration through entire scan time 400ms 400ms Duty cycle for high throughput operation 80% 90% Sn droplet diameter 30μm 30μm Collector reflectivity (area weighted ave. for unpolarized light) >50% >50% IF suppression (cleanliness) >10 10 >
8 EUV Power at IF and Dose Stability
9 In-Band EUV Power at I.F. (W) 70W EUV Power through 400ms Burst Duration July Results 40% duty cycle Time (sec) ~70W average EUV Power With fast transient decay Known cause 400ms burst duration 30μm droplet diameter In-band EUV Power at I.F. (W) September Results 60% duty cycle Time (sec) ~70W average EUV Power Without transient Known solution 400ms burst duration 30μm droplet diameter * Power is measured at plasma and calculated at IF using standard assumptions of 5 sr collection, 50% average reflectivity and 90% transmission 9
10 ~70W EUV Power at IF Continuous Operation 100 EUV Power at High Duty Cycle EUV IF power, W EUV Average EUV Maximum 60% duty cycle 400ms burst duration 30μm droplet diameter Droplet position control on Dose control off Time, min 70W at IF for 1 hour at 60% duty cycle ~ 150 kj per hr 24 hrs equivalent is 3.6MJ or 900 wafers per day (300mm, 10mJ/cm 2 ) 10
11 Closed Loop Dose Stability of <±0.35% meets Device Production Requirements In-band EUV Power at I.F. (W) Open Loop EUV Power in 10ms Window Time (ms) Open loop dose performance is <+/-11% (10ms window) In-Band EUV Power at I.F (W) Closed Loop EUV Power in 10ms Window Time (ms) Closed loop dose performance is <+/-0.35% EUV power level set point for closed loop control was 50W * Power is measured at plasma and calculated at IF using standard assumptions of 5 sr collection, 50% average reflectivity and 90% transmission 11
12 Debris Mitigation Validation
13 Debris Mitigation Protecting the collector from reflectivity degradation Change in Collector reflectivity is influenced by three factors: Fast ionic/neutral debris: causes sputtering/etching or implantation of/into collector surface (reflectivity degradation) Atomic debris: causes uniform layer deposition (absorption) MLM Coating Microparticle debris (droplets >100 nm): causes island growth (reflection degradation) MLM Coating MLM Coating 13
14 Hydrogen Buffer Gas Stops Ion Erosion and Implantation Simple, Effective, and Low Cost Laser Pulse Faraday Cup Signal, V E-3 H2 Pressure 0 P1 P2 P3 P3>P2>P E-3 tin ions electrons E-4 Reference Area Expose d Area E Sn Ion Energy, ev 2D reflectivity maps show <1% change between exposed and reference areas 2 hours exposure at 60W / 10% duty cycle 14
15 Hydrogen Buffer Gas Prevents Sn Deposition Simple, Effective, and Low Cost Without H 2 buffer gas the witness sample is opaque due to Sn deposition Glass witness sample placed at collector equivalent distance from plasma Testing verifies no net tin deposition using H 2 buffer gas 2 hours exposure at 8% duty cycle (30M pulses) Small droplets are the key to the success of this process With H 2 buffer gas the witness sample is transparent 15
16 5sr Far Field EUV Images at Low Duty Cycle Far Field EUV distribution taken at the beginning of the run with a fluorescence converter ~20W EUV exposure power Far field EUV distribution taken at ~4.5 hours into the run with a fluorescence converter ~20W EUV exposure power * Power in configuration with a 5 sr collector, measured at plasma assuming 50% average reflectivity and 90% transmission 16
17 5sr Far Field Images at High Duty Cycle Debris Mitigation System is Working Well 100 million pulses (2 hrs) 600 million pulses (9 hrs) 400 ms burst duration, 40% duty cycle, ~15W EUV Exposure Power Fluorescence converter limited to 40% duty cycle * Power in configuration with a 5 sr collector, measured at plasma assuming 50% average reflectivity and 90% transmission 17
18 Droplet Generator
19 Stable 30µm Droplets are Routinely Produced Droplet Positional Stability Dose Control Exposure Uniformity 30 µm droplets Droplet position, μm Droplet position, μm Time, sec Time, minutes Typical short term positional stability (no active stabilization) Typical long term positional stability (no active stabilization) 19
20 16µm Droplets Capability Recently Demonstrated Stable droplets with 16 µm diameter were produced for 200+ hours 16 µm droplets 200 µm Droplet Position, μm Position stability of the 16 µm droplets σ = 0.55 μm Time, sec 20
21 5sr Normal Incidence Collector
22 EUV Images of 5sr Collectors Collector 1 Collector 2 EUV image in the far field through IF was taken with a Zr coated fluorescence converter and CCD camera Second collector shows result of improved surface roughness, reflectivity and uniformity 22
23 5sr Collector Reflectivity Measurements Average Reflectivity Improved from 47% to 51% 51.0% average area-weighted reflectance for un-polarized light Improved from 47% on previous collector (shown at SPIE) Collector reflectivity measured at PTB using s-polarized light Sample reflectivity measured at PTB using un-polarized light Reflectivity of samples at each radius used to determine the collector reflectivity curve (red curve) for un-polarized light 23
24 MLM Coating Process Improvement Central Wavelength Meets Specification Center Wavelength wavelength [nm] collector # 2 collector # 3 collector # nm nm 13.5 nm nm substrate radius [mm] Please see PTB Poster 24
25 Intermediate Focus Protection
26 Source-Scanner Mechanical Interface Provides Cleanliness from Contamination Ar suppression Modeling Operating Region 10 6 RGA detection limit IFP Module Scaling H2 parameter Flow, slm (a.u.) Intermediate Focus Protection (IFP) is essential to keep contamination from passing through to the illumination optics Test data from our production system shows cleanliness with a standard aperture size is acceptable to the limit of RGA detection Ar gas used as probe gas to demonstrate suppression 26
27 HVM I Source Production
28 HVM I Source Production CLEANROOM Test bay area expanded Construction is complete Up to four systems can be built and operated in parallel HVM I Source module build and system integration are in process Multiple shipments planned in Q Source Vessel Drive Laser 28
29 Cost of Operation
30 LPP Source Electricity Cost Estimate Cost ($/yr) $220,000 $210,000 $200,000 $190,000 $180,000 $170,000 $160, Electrical Power (kw) Laser Power (kw) Cost ($/yr) Wall-Plug Power (kw) HVM I HVM II HVM III Power Consumption Total Source Module (kw) Availability / Utilization (Fully Utilized when Available) Source Operation Time (Percentage of Scanner Op Time) 85% / 100% 85% / 100% 85% / 100% 75% 60% 49% Electricity Cost* ($/kwhr) Cost ($/yr) $216k $197k $184k EUV electricity cost ~ 3X 193nm electricity cost * $0.07 $/kwhr Electricity Cost Nov 2008 (est.) - Energy Information Administration (Official Energy Statistics of US Government) 30
31 Roadmap and Summary
32 LPP EUV Source Roadmap EUV Source Power Roadmap HVM I HVM II HVM III Drive laser power (kw) >20 In-band CE (%) Collection Efficiency (sr) Collector Reflectivity (%) >60 >60 >60 Optical Transmission (%) Total EUV power at IF (W) >100 >200 >400 Laser Produced Plasma R&D HVM EUV Light Source Generations - Prototype shipment HVM I HVM II HVM III
33 Summary First source installed and operational at ASML Produced 50W EUV at IF in 400ms bursts at 60% duty cycle with <±0.35% dose stability Validated debris mitigation effectiveness on 5sr collector Hydrogen buffer gas provides simple, effective and low cost debris mitigation to both stop ions and prevent Sn deposition Collector reflectivity and uniformity has improved to >50% Droplet diameter shrink down to 30μm in production Production of multiple HVM I sources is on schedule to deliver to ASML as planned 33
34 Acknowledgements Please see our Poster #69 and Papers of our development partners ASML Erik Loopstra, Uwe Stamm, Christian Wagner, Noreen Harned University of Illinois at Urbana Champaign David N. Ruzic, Martin J. Neumann, R. E. Lofgren University of Central Florida Martin Richardson, Simi George University of California at San Diego Mark Tillack, Yezheng Tao Fraunhofer Institut f. Angewandte Optik und Feinmechanik Torsten Feigl, Hagen Pauer, Marco Perske, Sven Schröder, Sergiy Yulin Lawrence Berkeley National Laboratory Eric Gullikson, Farhad Salmassi Physikalisch-Technische Bundesanstalt Frank Scholze, Christian Laubis, Christian Buchholz National Institute of Standards and Technology Steven Grantham, Charles Tarrio 34
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