Cone and Block methods that sharply reduce logic simulation time in E-beam guided-probe diagnosis are proposed. These methods are based on a primitive-cell-level tracing algorithm, which traces faulty-state cells one by one in the primitive-cell level. By executing logic simulations in these methods so that simulated responses are reported only for the small set of nodes in a tracing path and in the immediate vicinity, simulation CPU time is sharply reduced with state-of-the-art logic simulators such as the Verilog-XL. With the proposed methods, the total CPU time in a diagnostic process can be reduced to 1/700 that of a conventional method. Additionally, the total amount of simulation date also reduces to 1/40 of its original amount. These methods were applied to the guided-probe diagnosis of actual 110k-gate ASIC chips and it was verified that they could be diagnosed in under seven hours per device, which is practical. This technology will greatly contribute to shortening the turnaround time of ASIC development.

Recent developments and case studies regarding VLSI device chip failure analysis are reviewed. The key failure analysis techniques reviewed include EMMS (emission microscopy), OBIC (optical beam induced current), LCM (liquid crystal method), EBP (electron beam probing), and FIB (focused ion beam method). Further, future possibilities in failure analysis, and some promising new tools are introduced.

A method to improve the efficiency of dynamic fault imaging (DFI) by fully utilizing the CAD data in the CAD-linked electron beam test system is proposed. In the method, in order to shorten the long acquisition time of the stroboscopic voltage contrast images over the whole area of the chip during the entire test cycle, only the area and phase (time) required for fault tracing are selected by utilizing the CAD data. Furthermore, image processing techniques are combined with the method to improve the efficiency of the DFI. In particular, the signal averaging technique is used in order to improve the signal-to-noise ratio in the stroboscopic images where all voltage information data on the equipotential electrode recognized by the CAD layout data are averaged. This enables us to reduce the acquisition time of images. Moreover, the experimental system is set up so that the image processing can be performed in parallel with the acquisition of the stroboscopic images. The proposed method is applied to part of a 2k-transistor block of a nonpassivated CMOS LSI where a marginal fault is detected. The result shows that the method is an efficient approach to the fully automatic fault diagnosis in the CAD-linked electron beam test system. The proposed method could improve the efficiency of the conventional DFI by a factor of more than 1000.

Following a discussion of various testing methods used in the electron beam (EB) test system, new waveform-based and image-based approaches in the CAD-linked electron beam (EB) test system are proposed. A waveform-based automatic tracing algorithm of the transistor-level performance faults is first discussed. Then, the method to improve the efficiency of an image-based method called dynamic fault imaging (DFI) by fully utilizing the CAD data is described. Third, the VLSI development cost is analyzed by using the fault models that make possible to take into consideration the effect of new testing technologies such as EB testing and focused ion beam (FIB) microfabrication. Finally, the future prospects are discussed.

An electron beam cell projection system has been developed that can effectively expose the fine, demagnified resultant pattern of repeated and non-repeated patterns such as the 256 Mb DRAM on a semiconductor wafer. Particular attention was given to the beam shaping and deflecting optics, which has two stage deflectors for the cell projection beam selection as well as the beam sizing, and three stage deflectors for objective deflection. The cell mask with a rectangular aperture and multiple figure apertures is fabricated by modified Si wafer processes. A new exposure control data for the cell projection is proposed. This data is fitted for the combination of pattern data for the cell mask projection and pattern data for the variable rectangular shape beam within the divided units of the objective deflection. On this exposure system, selective exposure of the desired pattern becomes possible on the semiconductor wafer while a mounting stage of the wafer is being moved, even if the pattern exposure of the repeated and non-repeated patterns is to be carried out. The total overhead time for selecting a subset of multiple figures and a rectangular aperture of the cell mask is less than 5 seconds/wafer. The estimated throughput of this system is approximately 20 wafers/hour.

An automatic tracing algorithm of the transistor-level performance faults in the waveform-based approach with CAD-linked electron beam test system which utilizes a transistor-level circuit data in CAD database is proposed. Performance faults mean some performance measure such as the temporal parameters (rise time, fall time and so on) lies outside of the specified range in a VLSI. Problems on automatic fault tracing in the transistor level are modeled by using graphs. Combinational circuits which consist of MOS transistors are considered. A single fault is assumed to be in a circuit. The algorithm utilizes Depth-First Search algorithm where faulty upstream interconnections are searched as deeply as possible. Treatment of the faults on downstream interconnections and on unmeasurable interconnections is given. Application of this algorithm to the 2k-transistor block of a CMOS circuit showed its validity in the simulation.

Material representations and algorithms are presented for simulation of nanometer lithography. Organic polymer resists are modeled as collections of overlapping spheres, with each sphere representing a polymer chain. Exposure and post-exposure bake steps are modeled at the nanometer scale for both positive and negative resists. The development algorithm is based on the Poisson removal probability for each sphere in contact with developer. The Poisson removal rate for a given sphere is derived from a mass balance relationship with a macroscopic development rate model. Simulations of electron beam lithography with (poly) methyl methacrylate and Shipley SAL-601 reveal edge roughness standard deviations from 2 to 3 nm, leading to linewidth peak-to-peak 3σ variation of 15 to 22 nm. Typical simulations require about 2 MBytes and under 5 minutes on a Sun Sparc 10/41 engineering workstation.

New focused ion beam (FIB) methods for microscopic cross-sectioning and observation, microscopic crosssectioning and elemental analysis, and aluminum film microstructure observation are presented. The new methods are compared to the conventional methods and the conventional FIB methods, from the four viewpoints such as easiness of analysis, analysis time, spatial resolution, and pinpointing precision. The new FIB methods, as a result, are shown to be the best ones totally judging from the viewpoints shown above.

The characteristics of an open-boundary Cherenkov laser for an electromagnetic wave with a continuous frequency spectrum are numerically analyzed. A given power spectral density for the input wave is found to get concentrated around the frequency where the spatial growth rate is maximum, as it grows along the electron beam. In addition, the frequency for the maximum growth rate is found to shift gradually to higher values. Furthermore, by gradually increasing the permittivity of the dielectric waveguide along it, we can always get the maximum power spectral density at the frequency where the spatial growth rate initially becomes maximum at the input.

A glass precursor resist (GPR) is designed on the basis of an idea of conversion of organosilicon polymer to an inorganic substance by lithographic procedure. Developed chemical amplification resist system is composed of poly (di-t-butoxysiloxane) and a photoacid generator. It has a high sensitivity of 1.6 µC/cm2, a resolution of 0.2 µm and an extremely high O2-RIE durability compared with bottom resist. Exposed film changed into silicate glass, and it was confirmed by IR spectra.

Three custom LSIs for EB60, a direct wafer exposure electron beam system, have been developed using 0.8 µm BiCMOS and SST bipolar technologies. The three LSIs are i) a shot cycle control LSI for controlling each exposure cycle time, ii) a linear matrix computation LSI for coordinate modification of the exposure pattern data, and iii) a position calculation LSI for determining the precise position of the wafer. These LSIs allow the deflection corrector block of the revised EB60 to be realized on a single board. A new adaptive pipeline control technique which optimizes each shot period according to the exposure data is implemented in the shot-cycle control LSI. The position calculation LSI implements a new, highly effective 2-level pipeline exposure technique, the levels refer to major-field-deflection and minor-field-deflection. The linear-matrix computation LSI is designed not only for the EB60 but also for a wide variety of parallel digital processing applications.