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Modeling and Simulation of Surface Roughness: Rajendra M. Patrikar
Modeling and Simulation of Surface Roughness: Rajendra M. Patrikar
Modeling and Simulation of Surface Roughness: Rajendra M. Patrikar
Abstract
With the technology advancement, electronic devices are miniaturized at every development node. Physical parameters such
as microscopic roughness are affecting these devices because surface to volume ratio is increasing rapidly. On all the real
surfaces microscopic roughness appears, which affects many electronic properties of the material, which in turn decides the yield
and reliability of the devices. Different type of parameters and simulation methods are used to describe the surface roughness.
Classically surface roughness was modeled by methods such as power series and Fast Fourier Transform (FFT). Limitations of
this methods lead to use the concept of self-similar fractals to model the rough surface through Mandelbrot–Weierstrass
function. It is difficult to express surface roughness as a function of process parameters in the form of analytical functions.
Method based on neural networks has been used to model these surfaces to map the process parameters to roughness parameters.
Finally, change in electrical parameters such as capacitance, resistance and noise due to surface roughness has been computed by
numerical methods.
# 2004 Elsevier B.V. All rights reserved.
0169-4332/$ – see front matter # 2004 Elsevier B.V. All rights reserved.
doi:10.1016/j.apsusc.2004.01.010
214 R.M. Patrikar / Applied Surface Science 228 (2004) 213–220
as micro-electro-mechanical systems (MEMS) [1–4]. r2, r3, . . ., rn is rotated in the parameter space. The field
Most of the surfaces grown are microscopically rough is ergodic because all the information about the joint
although topology may appear smoother on macro- distributions and their statistics can be obtained from a
scopic level. Advancements in the technology have single realization of the random field and one can use
lead to fabricate electronics system at molecular level. field average rather than ensemble average for all real
While it can be debated exactly how long it will take to surfaces. Thus, rough surface is usually assumed as a
develop a broadly based molecular manufacturing homogeneous, isotropic, and ergodic random field.
capability, experiments suggest that control and sta- Some of the first-order parameters which are used
bilization of molecular assemblies at the sub-nano- to represent the roughness are as follows.
meter scale are crucial steps in the fabrication of Here, Ra is the interface width, or RMS roughness,
molecular scale devices. However, the intrinsic sur- defined as
face properties such as roughness and other defects Z þ1
largely decide the formation of these devices [5]. Ra ¼ ðh hÞ2 f ðhÞ dh (1)
Formation of such molecular assemblies is also prone 1
to get disturbed by electrostatic forces among the Rave is the average roughness is also used to describe
molecules and the roughness may give rise intensity surface roughness, which is defined as the arithmetic
of these forces. Thus, it has become necessary to average of height h.
model surfaces to understand microscopic and macro- Z þ1
scopic phenomena to develop molecular electronics Rave ¼ jh hjf ðhÞ dh (2)
systems also. Most of the discussion here is based on 1
the software developed by us to simulate the surface The roughness is also represented by second-order
roughness. The first important step in these simula- statistics where the connection between random vari-
tions is to generate the rough surface with appropriate ables at different position represented. Most important
parameter. Since the quantification of roughness is characteristics of joint distribution is represented as
difficult, one needs to choose appropriate parameters auto-correlation function and it is defined as
to represent rough surfaces. In Section 2, we discuss Z Z
this aspect of surface modeling. 1 þ1 þ1
Rðr1 ; r2 Þ ¼ h1 h2 pj ðh1 ; h2 ; r1 ; r2 Þ dh1 dh2
Ra 1 1
(3)
2. Roughness models and parameters
where pj(h1, h2; r1, r2) is the joint distribution prob-
Various mathematical techniques are being tried out ability function of h(r1) and h(r2). An auto-correlation
to represent surfaces we get in real life [6]. There are function is an important function to describe the sur-
certain mathematical properties of the real life surface face roughness and depending on the nature of mor-
roughness. A random rough surface can be described phology appropriate function should be chosen.
mathematically as h ¼ hðrÞ, where h is the surface Commonly used functions are Gaussian, exponential
height of a rough surface with respect to a smooth and power law function, but other functions such as
reference surface defined by a mean surface height, Setch, Lorentzian, Bessel, and self-affine functions are
and r is the position vector on a reference surface. It is also used. Roughness can be represented by its fre-
a single-value function of the position vector, r (there quency properties and usually it is represented by
are no overhangs on the surface). For these surfaces power spectrum. The powers spectrum can be calcu-
height function is a random field with respect to lated from auto-correlation function. However, these
position. This field is also homogeneous since its parameters are instrument dependent. Consequently,
all joint probability distribution function remain the instruments with different resolutions and scan lengths
same when set of locations r1, r2, r3, . . ., rn is translated yield different values of these statistical parameters for
in the parameter space. The field is also isotropic since these surfaces. Therefore, it is important to character-
all the joint probability density functions are invariant ize rough surfaces using intrinsic parameters which is
after the after all the constellation of all the points r1, independent of sampling length which also adequately
R.M. Patrikar / Applied Surface Science 228 (2004) 213–220 215
describe the spatial information. The fractal models where x, y are the coordinate of the base plane are
are used to describe the surfaces to cater this need. taken as integer multiples of units, x ¼ 0; 1; 2 . . . ;
Fractals as are used recently because it helps to model ðM 1Þ and y ¼ 0; 1; 2 . . . ; ðN 1Þ, fk,l is the ran-
spatial variation through Mandelbrot–Weierstrass dom phase angles uniformly distributed over 0 and 2p.
function. Fractal dimension is defined by following In order to make this function real standard restrictions
equation [7]. are applied. Sk,l is the spectral density used to generate
surface and k and l are integers with k ¼ 0; 1; 2 . . . ;
logðNÞ M/2 and l ¼ 0; 1; 2; . . . ; N/2. We have used the auto-
D¼ (4)
logð1=rÞ correlation function for plotting the surface. The auto-
correlation function Rrs is given then spectral density
where D is the fractal dimension and r is the ratio of N is found out and above equation is used for plotting
parts scaled down from the whole. D is the fractal surface. The spectral density is calculated by follow-
dimension, which has a non-integer value varies ing equation:
between 1 and 2. In two dimensions increasing the
fractal dimension produces profiles, which are less X 1X
N 1
1 M kr ls
line like and more space filling, and so the fractal Sk;l ¼ Rrs exp i2p þ (6)
dimension can be thought of as a description of the MN r¼0 s¼0 M N
wiggliness of the surface. Hence, unlike RMS or
average values of roughness, the fractal dimension 3.2. Mandelbrot–Weierstrass function
contains spatial information as well as information on
profile deviation. One can calculate the fractal dimen- As mentioned earlier concept of self-similar fractals
sion from sampled morphology of rough surface by to model the rough surface is being used recently for
experimental methods. The data is divided in a square many applications. Previous studies [9] show that the
window (lx ly )and the variance (s2) calculations of single parameter fractal dimension (D) can quantita-
height function is done for each window. The data is tively describe surface microscopic roughness. The
plotted as log(s2) versus logðlx ly Þ, the fractal rough surface is modeled using the Mandelbrot–
dimension D is obtained as slope of this graph in Weierstrass function in this work represented by fol-
linear region. lowing equation:
X
1
Fig. 1. Surfaces drawn M–W equation for different values of D: (a) D ¼ 1:3, (b) D ¼ 1:5 and (c) D ¼ 1:8.
is useful to tune the model parameters since some of prescribed error margin. The weights are updated
the experimental data is recorded in terms of RMS by the following formula:
or some other parameters. In fact by adjusting the
Dwij ¼ 12 aee (8)
parameter D and k any profile can be generated and
fine-tuned. Fig. 1 shows the surfaces generated by where a is the learning factor, e the input, and e is the
Mandelbrot–Weierstrass equation and plotted by wire- difference between the desired RMS roughness para-
mesh models. meter and the calculated roughness of the surface
generated.
3.3. Artificial neural networks Thus, rough surface is usually assumed as a homo-
geneous, isotropic, ergodic random field and single
The surface roughness can also be modeled through value function. This implies that we could calculate
feed-forward network fairly easily [10]. Single node the error function by calculating roughness parameter
input layer was be chosen along with hidden layer and instead of calculating error at individual height func-
output layer represent z-coordinates. However, in tion and still it will be describing a desired surface
many applications such as integrated circuit technol- topology. Thus any parameter can be used to describe
ogy it is essential to understand the effect of process the surface and network can be trained.
parameters on the surface roughness to control the The network successfully produced a surface for
device properties. However, mapping process para- required roughness parameter. Although surface gen-
meters to the surface condition is little difficult with eration with this method is useful for calculating some
classical modeling methods. We are using neural
networks to model these surfaces to map the process
Hidden Output Layers
parameters to the roughness. Layers Wp1
A feed-forward network was set up to generate
multiple outputs that represented the z-coordinates Wp2
of the surface as shown in Fig. 2. The purpose of
the algorithm was to enable the network to learn the
necessary weights to generate a surface with a desired . .
roughness parameter. The configuration of network …….. Z-Co-
.
consist of a single variable and output layer consists Z Ordinates
or height variable over the surface. The RMS values . .
were calculated in each training epoch, but other
parameters could be calculated (which is implemented
in our software). The network is trained by simple
learning algorithm. The weights were updated till
calculated roughness parameter was within with a Fig. 2. Topology of the feed-forward network.
R.M. Patrikar / Applied Surface Science 228 (2004) 213–220 217
of the routine electrical parameter such as capacitance, mapping process parameters to the roughness. The
electric field variation and also for visualization pur- standard least mean square, gradient descent learning
pose, it is not very suitable to understand the effect procedure was used to update the weights. The para-
of processing parameters to be used for process devel- meters such as RMS values were calculated in each
opment or control. Any roughness parameters are a epoch by the formula given above.
complex function of processing conditions. For exam-
ple, polysilicon film roughness as function of some of Err ¼ 12 ðdrf orf Þ2 (9)
the processing parameters such as temperature, pres- where Err is the error function, drf the desired rough-
sure gas ratio have been studied and it was almost ness parameter and orf is the obtained roughness
difficult to find the analytical relationship for these parameter from the calculations. The sigmoid function
parameters. Thus, study of effect of process para- used as the transfer function is expressed as follows:
meters on the surface condition is little difficult with 1
classical modeling methods. In order to map process FðxÞ ¼ (10)
1 þ expðcxÞ
parameters to roughness parameters with neural net-
works back propagation algorithm with least mean The update relation for all the weights in the network
square gradient descent learning procedure can be is based on the computing change in the wij
used [11], which is described in Section 3.4.
Dwji ðnÞ ¼ a Dwji ðn 1Þ þ Zdj ðnÞyi ðnÞ (11)
3.4. The back propagation algorithm where a is the positive constant momentum constant,
Z the learning rate, dj a local gradient and yi is the
Multiple inputs were used to represent process input signal The network initially tested for arbitrary
parameters The input layer of the network consisted input parameters and surface of various roughness
process parameters such as temperature or pressure. were generated. But we have shown that this network
Initially Z values were generated by using random can be trained with experimental data and it can
values as weights. In this back propagation algorithm also predict the roughness for the process parameters
gradient descent method was used to search the weight [10].
solution during learning. The sigmoid activation func-
tion is used to normalize the network output. Fig. 3
shows the topology of the network used correct for 4. Calculations of electrical parameters
For example, by using this surface simulation, film approaches mean free path [13]. The resistance of
capacitance between two plates have been calculated these films are important because they contribute to
for various values of D. The top plate is perfectly signal delays and also the to the power dissipation. The
smooth and maintained at potential þV and bottom generic electrical resistance in a metal thin-film arises
plate is rough and placed at distance d which is due to electron scattering by phonons, point defects,
maintained at potential V. For simplicity value of impurities, grain boundaries and scattering with film
V was set to unity. surfaces. As the film thickness d decreases and
The capacitance per unit area was obtained from approaches its mean free path, the film resistivity
Gauss’ law as stated in following equation: increases due to an increased relative contribution
Z from surface scattering. Since roughness increases
e0 e @j
C¼ ðx; y; z0 Þ dA (12) total surface area resistance for very thin film also
V x;y @z
increases. But usually this happens for very thin metal
Following Laplace’s equation was solved to calculate films only. As the thickness of the metal increases the
the potential by finite difference method. contribution of surface scattering becomes very small
and the resistivity of smooth films and rough films
@2j @2j @2j
þ þ 2 ¼0 (13) become almost equal. Another mechanism, which is
@x2 @y2 @z
operative in very thin regime, is formation of small
Fig. 5 shows the normalized values of capacitance as a islands, which also is a cause of microscopic rough-
function of fractal dimension D. Increase in the capa- ness. The consequence of this morphology is that
citance is observed as the value of fractal dimension island boundaries serve as infinite potential barriers
increases. Another important parameter calculated resulting in infinite resistance arising from wide
was electric field. Because of the surface roughness separation between small cluster that nucleated during
electric field increases between two conductors. This early stage of film growth. However, as thickness
is important for dielectric reliability concerns as well grows separation between these island reduces and
as for signal integrity since signal coupling will be probability of electron tunneling from one island to
decided by this parameter. Since Laplace’s equation is another island increase, which results in the reduction
being solved here two-dimensional electric field con- of resistivity. Usually films are grown much thicker
tours can also be obtained and usually increased than infinite resistivity region. But at intermediate
electric field would be observed. level some of these mechanisms are operative simul-
Metal thin films are attractive option in integrated taneously.
circuits because it gives reduced fringing effects. The resistance of thin films can be computed by
However, effect of roughness on the resistance values Fuchs–Sodheimer (F–S) model. However, this model
needs attention for these films also if thickness of the does not take roughness into account. Namba’s model
R.M. Patrikar / Applied Surface Science 228 (2004) 213–220 219
calculate the effect of surface roughness by introdu- density is based on the electron tunneling between
cing surface roughness in terms of RMS values in hillocks on of the rough surface. The time required for
model [14]. This model the electron to jump from one hillock to another is
expressed as
rf 1
¼ (14)
rb 1 Aðk; pÞ t ¼ t0 expðjwÞ (18)
includes surface roughness in addition to surface and where j is the parameter governed by potential barrier
interface scattering in calculation of metal resistivity. of the material and vacuum. Distribution function for
Model calculates resistivity of thin metal films with w can be approximated by
following equation:
DðwÞ ¼ expðxwÞ (19)
Z 1
3 1 expðk=dÞ The final expression derived by taking summation
Aðk; pÞ ¼ ð1 pÞ ðd d 3 Þ dðdÞ
2k 0 1 p expðk=dÞ for w
(15) x=j Z j1
I 2 t0 ðC=NÞb x
Sðf Þ ¼ dx (20)
where rf is the film resistivity and rb is the bulk jð2pf Þg 1 þ x2
resitivity. And A(k, p) is defined as follows.In Namba’s
where I is the total current, C and b are the process
model [12], the roughness is approximated as a sine
dependant parameters, and N is the total number of
wave with sinusoidal undulations of amplitude h. At a
electrons inside the conductor. The value of g is given
distance x along the film thickness is given by follow-
by following expression:
ing equation:
x
2px g¼2 (21)
dNamba ðxÞ ¼ d0 þ h sin (16) 2j
l
The spectra was calculated for metal film (Cu) and
where d0 is the mean thickness and h is the amplitude. plotted for the different values of roughness. Fig. 5
We can use Namba’s model for resistance calcula- shows the variation of normalized spectral density
tions when surface modeled by fractals. We need to with surface roughness. Fig. 5 shows that the values
add thickness of the film to roughness. In the fractal of capacitance, resistance and noise change due to
model, the thickness is given by following equation surface roughness. It is important that these should be
and film can modeled. taken into account in the design of process and
dWM ðxÞ ¼ d0 þ sf ðxÞ (17) devices.
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