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Improving The Surface Metrology Accuracy of Optical Profilers by Using Multiple Measurements
Improving The Surface Metrology Accuracy of Optical Profilers by Using Multiple Measurements
Xudong Xu
Qiushi Huang
Zhengxiang Shen
Zhanshan Wang
Xudong Xu, Qiushi Huang, Zhengxiang Shen, Zhanshan Wang, “Improving the surface metrology accuracy
of optical profilers by using multiple measurements,” Opt. Eng. 55(10), 104105 (2016),
doi: 10.1117/1.OE.55.10.104105.
Abstract. The performance of high-resolution optical systems is affected by small angle scattering at the mid-
spatial-frequency irregularities of the optical surface. Characterizing these irregularities is, therefore, important.
However, surface measurements obtained with optical profilers are influenced by additive white noise, as indi-
cated by the heavy-tail effect observable on their power spectral density (PSD). A multiple-measurement method
is used to reduce the effects of white noise by averaging individual measurements. The intensity of white noise is
determined using a model based on the theoretical PSD of fractal surface measurements with additive white
noise. The intensity of white noise decreases as the number of times of multiple measurements increases. Using
multiple measurements also increases the highest observed spatial frequency; this increase is derived and cal-
culated. Additionally, the accuracy obtained using multiple measurements is carefully studied, with the analysis
of both the residual reference error after calibration, and the random errors appearing in the range of measured
spatial frequencies. The resulting insights on the effects of white noise in optical profiler measurements and the
methods to mitigate them may prove invaluable to improve the quality of surface metrology with optical profilers.
© 2016 Society of Photo-Optical Instrumentation Engineers (SPIE) [DOI: 10.1117/1.OE.55.10.104105]
Keywords: optical profilers; noise reduction; surface metrology; multiple measurements; power spectral density.
Paper 161136 received Jul. 17, 2016; accepted for publication Sep. 23, 2016; published online Oct. 14, 2016.
In Sec. 2, the basic theory underlying the PSD of white sources—the PSD of white noise has a constant value across
noise and fractal surfaces will be introduced; based on this frequency (that constancy being the reason for the term
theoretical framework, the problem of white noise in mea- “white”) and appears (ideally) as a horizontal straight line
surements obtained with optical profilers is discussed in in plots whose horizontal coordinate is the tangential spatial
detail. In Sec. 3, the multiple-measurement method is intro- frequency.30,36 The PSD of the white noise (and, therefore,
duced and evaluated as an approach to reduce the presence of the noise power, by integrating this density over the band-
white noise. A mathematical model of the multiple-measure- width) can be easily obtained by simply fitting a constant
ment technique is then proposed to calculate the intensity of value to its PSD.
the white noise. Finally, in Sec. 4, the highest spatial fre- To eliminate the leakage effect in the spectral estimate that
quency obtainable when using multiple measurements is results from having only finite-length data, a data window
carefully calculated, based on the model. The systematic function is used to smooth the ends of the observation seg-
accuracy of the residual reference error after calibration, ment. In this application, avoiding high sidelobe labels
and the random errors in the measuring spatial frequency (and, therefore, inaccuracies in the amplitude information
range are also carefully studied. of the PSD) is more important than frequency resolution.
Therefore, a Blackman window is chosen; this window
has a wide main lobe and low sidelobe levels, implying a
2 Theoretical Framework slightly diminished frequency resolution, but accurate ampli-
tude information, without disturbing artifacts generated by
2.1 Surface Characterization Using the Power sidelobes.35,37 Therefore, in this manuscript, all surface
Spectral Density height sequences are processed with a Blackman window
The surface figure and roughness can be specified in terms of before being Fourier transformed to obtain the PSD.
statistical quantities such as root-mean-square (rms) height
fluctuation and residual slope variation. However, to estimate 2.2 White Noise Effect
beamline system parameters, the surface errors should be
determined considering their spatial frequency bandwidth; The consequences of the presence of additive white noise in
evaluation of the PSD of surface errors is, therefore, the pre- the measurements are easily observable in the PSD of the
ferred method. The PSD of optical and engineering compo- measured data. To show this, a sample of Si material was
nents’ surfaces is a spectral description of the surface height characterized using an optical profiler based on phase scanning
measurements obtained from the surface topography. In interferometry (Contour GT-X3 from Bruker™). Figure 1(a)
practice, the PSD at the required frequency range can be shows a log–log plot of the PSD of the Si sample surface
extrapolated by fitting a more or less simple analytical obtained with the optical profiler and three different objectives.
model to the spectra measured with bandwidth-limited Figure 1(b) adds to these PSD curves obtained with AFM (for
instruments, such as the inverse-power-law PSD based on three different ranges), and the linear fitting line obtained with
fractal theory.35 The extrapolated PSD spectrum can then AFM data. Only the x-direction PSD is shown in this manu-
be used to simulate metrology data for x-ray optics before script, because the isotropic surface exhibits identical varia-
fabrication and predict the performance of the optical sys- tions on all tangential directions of measurement.
tem. When the PSD is obtained by multiple instruments As shown in Fig. 1, the different PSD curves obtained
or objectives of different but overlapping spatial frequency with the optical profiler and the three different objectives
ranges, the obtained data become more reliable. are not good matches to each other in the overlap frequency
According to fractal surface theory,35 the one-dimensional regions; they are also unable to connect harmoniously with
PSD follows an inverse-power-law Af−γ function, with the curves obtained by AFM. The reason for these imperfect
power parameter γ between 1 and 3. The measured PSD matches lies in the heavy tail that each one of these curves
spectra were typically found to be well approximated by an invariably presents, which can be very clearly observed in
inverse-power-law function with γ ≈ 2, especially for step Figs. 1(a) and 1(b). If these tail regions are disregarded,
phase elements of the appropriate height. Moreover, the the residual PSD curves become good matches to the straight
power parameter γ of many high-quality x-ray optics can be line of negative slope predicted by fractal surface theory. As
close to one. The expected surface height distribution can be mentioned in Sec. 2.1, white noise appears in the PSD as a
accurately predicted by the surface PSD, obtained in the constant value across frequency (a horizontal line in the PSD
medium-spatial-frequency range (approximately between plot). It may, therefore, be inferred (and will be shown to be
10−3 and 1 μm−1 ) with optical profilers, and in the high- the case) that the presence of white noise is the main cause for
spatial-frequency range (between 1 and 102 μm−1 ) with the observed tailing effect, which causes a clear leveling of the
AFM.29,36 According to the inverse-power-law, the PSD of PSD values. This effect has a noticeable influence in the mea-
a sequence with scale invariance (or fractal nature) is a straight surements, limiting their maximum effective spatial frequency,
line in a log–log plot, the absolute value of the line slope hav- and thereby decreasing spatial resolution. The white noise
ing a positive relation with the power parameter γ. levels of every single shot should, therefore, be reduced.
The term noise refers here to any additive undesirable sig-
nal that disturbs the transmission and decreases the resolu- 3 Multiple Measurements for White Noise
tion of optical profiler systems. The sources of noise may be Reduction
external or internal to the system. External noise includes
man-made noise, atmospheric noise, and other electromag- 3.1 Mathematical Model of Multiple Measurements
netic radiation signals, whereas internal noise includes ther- As mentioned above, additive white noise can be the main
mal noise, mechanical noise, and electrical noise.32 However, factor affecting the maximum effective spatial frequency
independently of the noise source—or, typically, the multiple range. As has been discussed, a common and simple method
K∕T ¼ cðTÞ − η:
EQ-TARGET;temp:intralink-;e002;63;209 (2)
−1
K∕T þ η γ
f max ¼ : (3)
A
EQ-TARGET;temp:intralink-;e003;63;433
Using the data measured for the used silica sample to fit
an inverse-power-law Af−γ, the following approximate
fractal parameters are obtained for the sample: A ¼ 0.050,
γ ¼ 2.3. To compare the highest spatial frequency intrinsic
to the instrument and the actual maximum spatial frequency
obtained in the white noise contaminated measurements, sev-
eral parameters were extracted for the T ¼ 1 and T ¼ 30
cases, with different objectives: optical resolution, sample
resolution, and the corresponding highest spatial frequency.
The results are listed in Table 2.
According to the profiler’s manual, the inherent resolu-
tions of the 2.5× and 10× objectives are limited by the
Nyquist frequency, whereas the inherent resolution of the
50× objective is limited by the Rayleigh criterion. How-
ever, in actual measurement, the obtained highest spatial Fig. 5 Surface measurements of the same area obtained with the
frequency is far less than the intrinsic parameter of the instru- optical profiler (10× objective lens) for multiple measurements with
different values of T . (a) T ¼ 1, (b) T ¼ 10, and (c) T ¼ 30.
ment, as shown in Table 2. The highest spatial frequency in
the T ¼ 30 case is, however, approximately four times
higher than that of single measurements; that is why the top-
ology shown in Fig. 5(c) shows more surface detail than 4.2 Accuracy of the Optical Profiler Using Multiple
Measurements
Figs. 5(a) and 5(b). The degree of increase of the highest
spatial frequency will be somewhat influenced by the param- To evaluate the accuracy of the optical profiler using multiple
eter γ of the sample being measured. The parameter γ can measurements, both the systematic and random error com-
directly influence the index term in Eq. (3). According to ponents must be considered. The reference surface error is
Eq. (3), the highest spatial frequency increases when the the most influential systematic error in optical profiler mea-
parameter γ increases. surements. A common method to calibrate the reference
5 Conclusion
The deleterious effects of the presence of white noise in
optical profiler measurements based on phase scanning inter-
ferometry are very apparent when the measured data are
characterized by its PSD; the presence of white noise is
Fig. 6 Averaged PSD of the 30 residual surfaces, using a 2.5× considered to be the main cause of diminished maximum
objective. effective spatial frequency and reduced accuracy in optical
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This work was sponsored by the National Natural optics—understanding how to specify and characterize optics,” in The
Science Foundation of China (No. 11443007), NSAF 3rd Int. Workshop on Metrology for X-ray Optics, Pohang Accelerator
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Fundamental Research Funds for the Central Universities. Optik–Int. J. Light Electron Opt. 125(17), 4685–4688 (2014).
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