B. Dirahoui’s scientific contributions

This work presents a 32 nm SOI CMOS technology featuring high-k/metal gate and an SRAM cell size of 0.149 mum². V_min operation down to 0.6 V in a 16 Mb SRAM array test vehicle has been demonstrated. Aggressive ground rules are achieved with 193 nm immersion lithography. High performance is enabled by high-k/metal gate plus innovation on strained silicon elements including embedded SiGe and dual stress liner (DSL). Gate lengths down to 25 nm have been demonstrated enabling performance without the power penalty from gate capacitance. AC drive currents of 1.55 mA/um and 1.22 mA/um have been achieved at an off-state of 100 nA/mum and V_DD of 1 V for NFET and PFET, respectively. For the first time, we have also demonstrated that SOI maintains performance benefit over bulk silicon in high-k/metal gate and 32 nm ground rules.

With the nominal gate length at the 65 nm node being only 35 nm, controlling the critical dimension (CD) in polysilicon to within a few nanometers is essential to achieve a competitive power-to-performance ratio. Gate linewidths must be controlled, not only at the chip level so that the chip performs as the circuit designers and device engineers had intended, but also at the wafer level so that more chips with the optimum power-to-performance ratio are manufactured. Achieving tight across-chip linewidth variation (ACLV) and chip mean variation (CMV) is possible only if the mask-making, lithography, and etching processes are all controlled to very tight specifications. This paper identifies the various ACLV and CMV components, describes their root causes, and discusses a methodology to quantify them. For example, the site-to-site ACLV component is divided into systematic and random sub-components. The systematic component of the variation is attributed in part to pattern density variation across the field, and variation in exposure dose across the slit. The paper demonstrates our team's success in achieving the tight gate CD tolerances required for 65 nm technology. Certain key challenges faced, and methods employed to overcome them are described. For instance, the use of dose-compensation strategies to correct the small but systematic CD variations measured across the wafer, is described. Finally, the impact of immersion lithography on both ACLV and CMV is briefly discussed.

The lithographic challenges of printing at low-k1 for 65 nm logic technologies have been well-documented (1,2). Heavy utilization of model-based optical proximity correction (OPC) and reticle enhancement technologies (RET) are the course of record for 65 nm logic nodes and below. Within the SRAM cells, often more dimensionally constrained than random logic, characterization of the nominal gate linewidth and linewidth variation is critical to ensure cell performance and stability. In this paper, we present the use of the linewidth roughness analysis package of a commercially-available CD SEM to extract low-spatial frequency information in order to characterize effects of OPC, substrate topography, process variations, and RETs. The SEM-based characterization of across-device linewidth variation is analyzed statistically to extract the information necessary to set device processing conditions and to make layout corrections consistent with producing the least possible channel length variation along the active device.

We report, for the first time, a detailed study of intra-die variation (IDV) of CMOS inverter delay for the 65nm technology, driven by mm-scale variations of rapid thermal annealing (RTA). We find that variation in V_T and R_EXT accounts for most of the IDV in delay and leakage and is modulated by lamp RTA ramp rate. We show a good correlation of inverter delay to mm-scale variation in the predicted reflectivity of the device pattern densities

A high performance 65 nm SOI CMOS technology is presented featuring 35 nm gate length, 1.05 nm gate oxide, performance enhancement from dual stress nitride liners (DSL), and 10 wiring levels with low-k dielectric offered in the first 8 levels. DSL enhancement is shown to scale well to 65 nm with larger enhancement seen than at 90 nm design rules. A high performance 0.65μm² SRAM cell is also presented. SOI allows the SRAM cell to use Metal 1 instead of Metal 2 for bit-line wiring, which lowers the capacitance and improves access times. A functional dual-core microprocessor test chip containing 76Mb SRAM cache and key execution units has been fabricated.