To reduce the surface roughness of a substrate for mask blanks for extreme ultraviolet (EUV) lithography, the layers of
a Mo-Si multilayer structure being deposited by magnetron sputtering were treated with an assisted ion beam. The
effectiveness was analyzed by atomic force microscopy, X-ray reflection diffraction, and EUV reflectivity
measurements, which revealed a large improvement in the interface and surface roughness, resulting in a multilayer
with better EUV performance than one formed without such treatment.
We evaluated TaSix-based bi-layer absorber on ZrSi-based buffer for EUV mask, especially
considering the possibility of ZrSi-based film as a combined buffer and capping layer. Since
ZrSi-based film has both high dry-etching resistance and EUV transparency, it has potentiality to
work as a combined capping and buffer layer. AFM machining repair of bi-layer TaSix absorber
on ZrSi-based buffer can be performed to good profile. Printing evaluation showed that
over-repair into buffer layer did not affect significantly to wafer CD. FIB (10keV) repair of
bi-layer TaSix absorber on ZrSi-based buffer needs improvement for side-wall profile and
distinguishable evaluation from implanted Ga+ effect in more detail. Effect of FIB (10keV) scan
with ordinary repair process seems to be at least smaller than 10%.
To find the most suitable setup of the Mo and Si targets and substrate for the formation of Mo-Si multilayers with a low defect density, three deposition configurations (upward, horizontal, and off-axis) for magnetron sputtering (MS) were studied. It was found that the horizontal configuration yielded the lowest defect count and was also the best for ion beam sputtering (IBS). A defect density as low as 1 defect/cm2 has been achieved for Mo-Si multilayers grown by IBS or MS. A new approach to reducing the thickness of the interface layer between Mo and Si layers that involves the use of an assisted ion beam (AIB) was found to be effective. Transmission electron microscopy revealed that, during MS, AIB treatment of a Si surface before deposition of a Mo layer reduced the thickness of the interface layer to zero. Angle-dependent X-ray diffraction measurements of multilayers showed sharp reflection peaks, indicating considerable improvement in the interface structure.
Ion beam sputtering and magnetron sputtering were used to grow Mo-Si multilayer structures to investigate which is more suitable for the fabrication of mask blanks for extreme ultraviolet (EUV) lithography. For ion beam sputtering, the difference between using Ar and Xe as the sputtering gas was also examined. For ion beam sputtering, the peak EUV reflectivity of 40 Mo-Si bilayers was measured to be about 62% at wavelengths in the range of 12-15 nm; while for magnetron sputtering, the value was 65%. A transmission electron microscopy analysis of multilayers deposited by ion beam sputtering revealed an interface layer between the two materials: It had a thickness of 1.5 ± 0.2 nm when Mo was deposited on Si, and a thickness of 0.7 ± 0.2 nm when Si was deposited on Mo. These interface layers were 30-50% thicker than those formed during magnetron sputtering. The mechanism by which interface layers form is discussed based on an ion implantation model.
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