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Results in Physics 54 (2023) 107146

Contents lists available at ScienceDirect

Results in Physics
journal homepage: www.elsevier.com/locate/rinp

An improved method for measuring epi-wafer thickness based on the


infrared interference principle: Addressing interference quality and
multiple interferences in double-layer structures
Jiaxing Sun a, Zhisong Li a, *, Haojie Zhang a, Jinlong Song b, Tianbao Zhai a
a
College of Machine, Shanghai Dianji University, Shanghai 201306, PR China
b
FabXLab (Ningbo) Semiconductor Equipment Co.,Ltd, Shanghai 201114, PR China

A R T I C L E I N F O A B S T R A C T

Keywords: The precise measurement of the thickness of substrate and epitaxial layers in epi-wafers is essential in the
Bilayer film thickness measurement semiconductor chip fabrication process. This study presents a new method for measuring the thickness of epi-
Infrared interferometry wafers using Fourier Transform Infrared (FTIR) technology, which allows for precise, simultaneous, and fast
Variational mode decomposition
measurement of both substrate and epitaxial layers. To address the low accuracy of traditional FTIR techniques, a
Lomb-Scargle periodogram
One-dimensional signal processing
novel VMD-LSP algorithm is introduced, capable of precisely extracting frequency components from the original
spectral signal to calculate the precise thickness of the substrate and epitaxial layers. This study also introduces
an adaptive spectral excision algorithm and a high-precision thickness extraction algorithm to handle variations
in the infrared light absorption of different epi-wafer materials, leading to weakened interference signals, and the
challenges that stem from the unique double-layer structure of the wafer. These algorithms efficiently reduce the
impact of poor spectral quality and multiple interferences on measurement results, resulting in improved mea­
surement accuracy and stability. During the experimental phase, we compared our results obtained by ellips­
ometry as truth to evaluate the accuracy and stability of our proposed method. The results show an 85%
reduction in measurement error and a 65% improvement in stability compared to traditional methods. As a
result, our method meets the need for fast and efficient epi-wafer thickness measurement in semiconductor chip
manufacturing, providing a feasible and effective solution to the challenge of epi-wafer thickness measurement.

Introduction Methods such as scanning electron microscopy (SEM) use thin elec­
tron beams to scan samples, producing clear images of sectional
Chips are key components in electronic devices and play a crucial morphology through the interaction between electron beams and sam­
role in various fields. In the chip manufacturing process, over 95 % of ples[11]. However, such methods lack online measurement capabilities
integrated circuits and semiconductor devices are fabricated on epi- and are not suitable for industrial production due to possible surface
wafers[1,2]. Epi-Wafers preparation includes substrate preparation and damage and extended measurement times[12]. In contrast, optical
epitaxial processes. Epitaxy processes are used to grow high-resistance measurement methods effectively address these issues. Currently, the
epitaxial layers on low-resistance substrates, overcoming the break­ primary optical measurement methods include ellipsometry and
down and saturation voltage drop problems of conventional silicon Fourier-transform infrared (FTIR) spectroscopy. Spectroscopic Ellips­
semiconductor devices[3–5]. Appropriate substrate and epitaxial ometry (SE) is a polarized light based measurement technique that is
thickness not only provide a stable foundation for the precise positioning widely used to measure surface structures and dimensional or optical
and interconnection of the chip’s functional components but also ensure parameters of surface layers[13]. In this method, ellipsometer parame­
the precise positioning and arrangement of the chip’s internal elements, ters are obtained by measuring the relative amplitude and phase
thereby achieving the expected circuit functionality[6–8]. Conse­ changes of polarized light reflected from the material surface[14,15].
quently, the thickness of the substrate and epitaxial layers is an impor­ However, for the measurement of optical films such as wafer samples,
tant parameter in the epi-wafer quality inspection process[9,10]. calculations and fitting are required to obtain the optical parameters of

* Corresponding author.
E-mail address: song272808216@163.com (Z. Li).

https://doi.org/10.1016/j.rinp.2023.107146
Received 28 August 2023; Received in revised form 28 October 2023; Accepted 30 October 2023
Available online 31 October 2023
2211-3797/© 2023 The Author(s). Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-
nc-nd/4.0/).
J. Sun et al. Results in Physics 54 (2023) 107146

the film[16]. Therefore, spectroscopic ellipsometry is an indirect mea­ employed. However, as precision requirements continue to escalate
surement method, and the accuracy of its results depends not only on the within practical industrial production, a corresponding augmentation in
measurement accuracy of the ellipsometer itself, but also on the data sampling points becomes imperative. Existing Lomb-Scargle
appropriate selection of film structures, evaluation parameters and Periodogram computation methods may fall short of meeting the effi­
dispersion models[17,18]. Furthermore, ellipsometry has limitations ciency and rapid measurement demands prevalent in industrial pro­
when measuring thick films, ellipsometry methods display thickness duction. Addressing the aforementioned challenges encountered during
periodicity for films thicker than 10 μm[19]. Consequently, there are practical measurements necessitates further research and the develop­
multiple uncertain values for films with unknown range thicknesses, ment of novel technologies and methodologies to facilitate the appli­
which impedes rapid measurement[20]. Fourier Transform Infrared cation of infrared interference technology in measuring the thickness of
interferometry is a technique that offers significant advantages for epitaxial semiconductor wafers.
measuring the thickness of optical films[21]. This method collects the This essay offers a swift, highly precise, and simultaneous method for
reflected spectrum formed by the interference of reflected light beams measuring the thickness of both the epi-wafer substrate and the epitaxial
from the upper and lower surfaces of a thin film, and then uses time- layer, using the Fourier Transform Infrared (FTIR) interferometry prin­
domain-frequency-domain analysis methods such as Fourier transform ciples. Firstly, while dealing with the raw spectral signals, we introduce
to calculate the maximum frequency of its reflected spectrum, thereby an adaptive spectral excision algorithm that filters out lower-quality
obtaining the thickness information of the sample[22–24]. Although the spectral segments. This results in better accuracy of the subsequent
thickness measurement accuracy of Fourier transform infrared tech­ analysis. Secondly, during the transformation from time-domain to
nology cannot match that of spectroscopic ellipsometry, this method frequency-domain, we propose the VLA (VMD-LSP Algorithm) method.
reduces the dependence on scattering models and simplifies the mea­ This algorithm accurately extracts primary frequency components from
surement process, making it suitable for the optical properties of most the signal which represents thickness information. Thus, it enhances the
films[25,26]. In addition, this method is less affected by environmental accuracy and reliability of the measurement results. Finally, while dis­
factors and is very suitable for situations where accurate and rapid cussing thickness extraction, we propose a new high-precision thickness
measurement is required in industrial production[27]. extraction algorithm. This algorithm successfully eliminates noise
In our prior research endeavors, we crafted a methodology predi­ interference signals introduced by ambient light or mechanical vibra­
cated upon Fourier-transform infrared technology, aimed at measuring, tions. It enables us to extract epi-wafer substrate and epitaxial layer
and calibrating the thickness of single-layer semiconductor thin films thickness with more accuracy, tackling the difficulties faced by tradi­
[28]. A plethora of experiments were undertaken, validating the tional techniques in measuring multilayer film thickness.
method’s suitability for gauging single-layer semiconductor film thick­
ness. Nonetheless, for the more commonly employed epitaxial wafers Method
within the semiconductor industry, employing this technique for
thickness measurement unveils substantial constraints. (1) Epitaxial This chapter introduces the principles of measuring epi-wafer
wafers in the semiconductor domain typically consist of a substrate with thickness using FTIR technology and the innovative algorithms pro­
a thickness on the order of hundreds of micrometers and an epitaxial posed for this purpose. The VLA algorithm, the adaptive spectral exci­
layer, often several ten micrometers or even thinner. These two strata sion algorithm, and the high-precision thickness extraction algorithm
may utilize identical semiconductor materials or distinct ones. However, are among the algorithms described in this chapter. They have been
the optical characteristics of the substrate and the epitaxial layer differ designed to enhance the accuracy and reliability of measuring the
due to the use of different semiconductor materials or different doping thickness of semiconductor epi-wafer substrates and epitaxial layers,
concentrations. In Fourier transform infrared interference thickness offering a solution for this purpose.
measurement, this is manifested as a difference in the infrared absorp­
tion ability of the substrate and the epitaxial layer. Therefore, when the Principle of infrared interferometric thickness measurement
semiconductor material has a strong absorption ability for infrared light,
this leads to weak reflected light and poor interference quality. More­ Fig. 1 demonstrates the interferometric thickness measurement
over, currently prevalent SLED and LED light sources in the market do principle. Subfigure (a) presents an epi-wafer sample containing a thin
not exhibit uniform power distribution within their spectral range. epitaxial layer and a comparatively thick substrate, resulting in three
Therefore, within lower-power spectral bands, interference phenomena reflective surfaces from these two dielectric layers. Therefore, the inci­
may not occur at all. (2) Similarly, owing to the dual-layer architecture dent light (I0) passes through these three surfaces in sequence, under­
inherent to epitaxial wafers, when employing the method proposed in going reflection and resulting in interference within the interferometric
our prior research, incident light often undergoes multiple reflections cavity. This ultimately leads to the creation of a reflection spectrum, as
within the epitaxial wafer. This occurrence results in the presence of illustrated in subfigure (b). The reflection spectrum (R) is mathemati­
multiple thickness peaks within the frequency domain of the reflectance cally represented as follows[27,30]:
spectrum, posing a challenge for the final thickness extraction. (3) In our ⎧ ( )
prior study, we employed Empirical Mode Decomposition (EMD) as a √̅̅̅̅̅̅̅̅̅̅̅
⎨ R(z, λ) = R1 + R2 + 2 R1 ⋅R2 ⋅cos 2πz

high-pass filter. However, for dual-layer and even multi-layer semi­ λ (1)

conductor thin-film structures like epitaxial wafers, EMD is no longer a ⎩
z = 2ndcosθ
viable choice. EMD is entirely data-driven, and the number of modes (K)
generated during decomposition is solely dictated by the sample data, where R1 represents the background profile of the light source. R2 de­
rendering it uncontrollable. Consequently, for single-layer thin films, we notes the intensity of diffusely reflected interference beams within op­
could assume that the signal component representing thickness was tical elements like optical fibers and probes. z signifies the optical path
superimposed within the highest frequency mode, Imf1, extracted during difference between the two reflected beams; λ represents the wavelength
decomposition. Conversely, for multi-layer thin films, simultaneous of the light source, n signifies the refractive index of the medium be­
extraction of multiple thickness components is requisite. Continued use tween the two interfering beams, and d corresponds to the thickness of
of the EMD decomposition method could lead to different thickness the medium[31].
signal components being superimposed within various modes, falling FTIR technique deduces thin film thickness by analyzing the fre­
short of the rapid industrial measurement requisites. (4) In our prior quency f of the reflected spectrum. In Equation (1), considering 1/λ as
research, an accelerated computation technique for the Lomb-Scargle time t, the optical path difference z becomes analogous to the frequency f
Periodogram (LSP), as introduced by Press and Rybicki[29], was of a cosine signal. Consequently, through the computation of the

2
J. Sun et al. Results in Physics 54 (2023) 107146

Fig. 1. Infrared interferometric thickness measurement principle. (a)Interference model; (b)Reflectance spectrum; (c) Thickness calculation;

frequency f in the reflected spectrum, thin film thickness can be solved and the time-offset τ is defined by:
using Equation (1). (∑ )
In the case of epi-wafer samples with a bilayer structure, three peaks 1 sin(4πf λi )
τ= tan− 1 ∑ i (4)
emerge upon frequency calculation of their reflective spectra, as illus­ 4π f i cos(4π f λi )
trated in Fig. 1(c). These peaks correspond to the thickness of the
The major concern with the LSP algorithm lies in its computational
epitaxial layer, de, the thickness of the substrate, ds, and the sum of both
complexity. If the method of approximating trigonometric functions
thicknesses, dsum, respectively.
using Taylor series expansion is employed, the overall computational
complexity can easily reach O(N2). Leroy B[36], in pursuit of enhanced
An improved method of frequency calculation (VMD-LSP Algorithm) efficiency, leveraged the Fast Fourier Transform to refine the conven­
tional LSP algorithm. Without compromising solution accuracy, this
According to equation (1), it is easy to see that if the wavelength λ is modification reduced the computational complexity to O(log N),
viewed as a time increment t, then the reflection spectrum signal R is a resulting in nearly a fivefold reduction in computation time. The Fast
non-stationary signal whose oscillation frequency decreases with LSP algorithm begins by defining four coefficients:
increasing λ. Therefore, traditional Fourier transform methods cannot ∑ ∑
meet the accuracy requirements when extracting the maximum fre­ SR = (R(λi ) − R )sin(2π f λi ), CR = (R(λi ) − R )cos(2πf λi )
quency of the reflection spectrum signal R. To accurately extract the i
∑ i
∑ (5)
maximum frequency of the original spectral signal, this paper proposes a S2 = sin(4π f λi ), C2 = cos(4πf λi )
method called VMD-LSP Algorithm (VLA). The method uses Variational
i i

Mode Decomposition (VMD) to filter the original spectrum and calcu­ The refined LSP formula is as follows:
lates the Lomb-Scargle periodogram of the high-frequency component {
after decomposition to achieve more accurate thickness calculation. By 1 [CR cos(2πf τ) + SR sin(2πf τ)]2
P(f ) = 2
using the VMD algorithm, we can effectively reduce the influence of the 2σ N + C2 cos(4πf τ) + S2 sin(4πf τ)
infrared light source base signal, separate the cosine signal with thin film }
[SR cos(2π f τ) − CR sin(2πf τ)]2
thickness information from the interference signal generated by diffuse + (6)
reflection inside the optical fiber and optical probe, and improve the N − C2 cos(4πf δ) − S2 sin(4πf τ)
calculation efficiency of LSP algorithm. Compared with Fast Fourier
Transform (FFT) method, VLA algorithm performs better in processing Variational mode decomposition
non-stationary signals and can better eliminate noise interference, In 2013, Dragomiretskiy et al. proposed a novel completely non-
making it more suitable for extracting the maximum frequency of the recursive variational mode decomposition (VMD) method. This
original spectral signal. method transforms mode decomposition into a variational solution
problem and uses the alternating direction multiplier method for opti­
Lomb-Scargle periodogram mization[37]. In the process of optimization, an ensemble of modes with
The Lomb-Scargle periodogram (LSP), based on the discrete Fourier band-limited characteristics is obtained[38]. Specifically, the core of
transform, effectively identifies periodic components in non-uniform Variational Mode Decomposition (VMD) is to construct a variational
time series[32,33]. Its central idea involves using sine functions to problem that exploits the principles of classical Wiener filtering, Hilbert
non-linearly fit data sequences for estimating power spectral density. transforms, and down-mixing to decompose multi-component signals
For the reflected spectrum R(λi) obtained from the spectrometer, where i into multiple Intrinsic Mode Functions (Imfs). Here, the Wiener filter is
= 1,2… N, the periodogram at frequency ’f’ is defined as[34,35]: used to denoise the signal, while the Hilbert transform acts as a spectral
{ [∑ 2]
domain multiplier, producing an analytical single-sideband signal[39].
P(f ) =
1 i (R(λi ) − R )cos[2π f (λi − τ) ]
∑ During the decomposition process, the sum of the bandwidths is mini­
2σ 2 i cos [2π f (λi − τ) ] mized by iteratively searching for limited bandwidth and the optimal
2

[∑ 2]
} center frequency to ensure that the component signals are equal to the
i (R(λi ) − R )sin[2π f (λi − τ) ]
+ ∑ 2 (2) original signal. This method determines the number of Imfs and allows
i sin [2π f (λi − τ) ]
the output of the Imfs to be controlled based on practical considerations.
Each Imf can be represented as follows:
where R and σ2 are the mean and variance of the measurements,
respectively, given by: uK = AK (t)cos[φK (t)] (7)

1∑ 1 ∑ where, AK(t) represents the instantaneous amplitude of uK, φK(t) denotes


R= R(λi ), σ2 = (R(λi ) − R )2 (3)
N i N− 1 i the instantaneous phase, and t denotes time.

3
J. Sun et al. Results in Physics 54 (2023) 107146

The constrained optimization problem for constructing each Imf is modulated by the power curve of the light source, which will un­
component in VMD can be formulated as[40]: doubtedly introduce errors into the final measurement results. After
⎧ { ⃦ [( ) ] ⃦2 } conducting extensive experiments, we found that after VMD decompo­
min ∑⃦ ⃦



⎪ ⃦∂t δ(t) + j ∗ uK (t) e− jwK t ⃦ sition of the reflected spectral signal, Imf1 reflects the power distribution
⎨ ⃦ ⃦
({uK }, {ωK } ) K πt curve of the light source, as shown in Fig. 2(b). Therefore, we discard
(8)
2



∑ Imf1 and only calculate Lomb-Scargle periodograms for Imf2 to eliminate
⎪ s.t. u (t) = f (t)
⎩ K
interference signals introduced by the light source. Secondly, it can
K
improve measurement efficiency. Based on the characteristics of VMD
where f(t) represents the original signal, [14]= {u1, u2, …, uk} represents algorithm, the mean of all Imf components is approximately 0 and their
the K finite bandwidth Imfs obtained from the decomposition, {ωK} = variance is approximately 1. If we calculate the Lomb-Scargle periodo­
{ω1, ω2, …, ωk} represents the center frequencies of the Imfs, δ(t) is the grams for Imf2, then R in equation (6) equals 0 and σ 2 equals 1. This can
Dirac function, * denotes the convolution operator, and j is the imagi­ further speed up calculation speed based on fast LSP algorithm and thus
nary unit. improve detection efficiency.
Next, by utilizing the Lagrange multiplier algorithm with quadratic Fig. 2 demonstrates the complete process of the VLA algorithm. The
penalty terms, the problem is transformed into an unconstrained vari­ reflectance spectrum is decomposed using VMD, and the Imf2 compo­
ational problem, leveraging the convergence of quadratic penalty under nent is subsequently subjected to the peak extraction method to deter­
finite weights and strict enforcement of Lagrange multiplier constraints. mine the maximum frequency f of the Lomb-Scargle periodogram. By
Therefore, the extended Lagrange expression L is given as[41]: merging Equation (1), the thickness of the thin film can be ascertained as
⃦2 ⃦ follows:
∑⃦ ⃦
[(
j
) ]
⃦ ⃦ ⃦

L({uK }, {ωK }, λ ) = α ⃦∂t δ(t) + ∗ uK (t) e − jwK t ⃦
f (t)
π t ⃦ +⃦⃦ d=
fpeak
(11)
K 2
⃦2 〈 〉 2n
∑ ⃦ ∑

− uK (t) ⃦ + λ(t), f (t) − uK (t) (9) where fpeak is the peak horizontal coordinate of the periodogram and n is

K 2 K the refractive index of the epi-wafer sample. Due to the bilayer thickness
structure of the wafer, three distinct thickness peaks arise, as illustrated
where, λ(t) represents the Lagrange multiplier operator and α is the
in Fig. 2(c).
balance parameter for the data fidelity constraint, which was set to 3000
in this study. Finally, the Alternate Direction Method of Multipliers
(ADMM) is employed to identify the saddle point of the above function New algorithm for epi-wafer interference problem
and solve the original minimization problem. The solution process in­
volves iterative updates of uK, ωK, and λ until the optimal solution of the By using the VLA method described in Section 2.2, we can accurately
above function is obtained. By following these steps, the VMD decom­ isolate the original spectral signal components that solely represent epi-
position is completed, resulting in K Imf components. wafer thickness information and accurately extract their maximum
The VMD method has shown a strong ability to solve mode mixing frequency, thereby obtaining a more accurate thickness value using
and misclassification problems due to non-iterative calculation and Equation (11). However, due to the non-uniformity of the epi-wafer
adaptive narrowband determination procedures. While VMD has material itself and variations in its microstructure, different epi-wafer
demonstrated better performance than traditional decomposition samples of different materials exhibit differences in their absorption
methods, its success significantly depends on preset parameters capacity in the infrared band. In addition, the reflectivity of the sub­
including mode number K and bandwidth control parameter α. Hence, strate and epitaxial layer varies. As a result, the raw spectral interference
selecting appropriate parameters to optimize the performance of VMD obtained for epi-wafers of certain specific materials (e.g. AL2O3) is often
has become a critical research issue. of poor quality. Furthermore, when infrared interferometry is used to
measure epi-wafer thickness, the unique two-layer structure of the epi-
Thickness calculation formula based on VLA wafer often leads to secondary or multiple interferences, resulting in
Using VMD decomposition technology in conjunction with Lomb- the presence of more than three peaks in the periodogram. These
Scargle periodograms has two significant advantages. (1) it can elimi­ problems pose significant challenges to the final calculation and thick­
nate interference caused by the light source. For LED and SLED light ness extraction.
sources widely used in the market, their power is not uniformly
distributed within the wavelength range. In most cases, the power at the Adaptive spectral excision algorithm
center wavelength of the light source is the highest, and the power on Fig. 3 illustrates a situation where the interfering signal is weak and
both sides gradually decreases, exhibiting a Gaussian distribution. the spectral quality is poor. In Fig. 3(b), In the low frequency region of
Therefore, as shown in Fig. 2(a), the actual collected reflection spectrum the original spectrum, the interference quality is extremely poor, the

Fig. 2. VLA algorithm processing (K = 2).

4
J. Sun et al. Results in Physics 54 (2023) 107146

Fig. 3. Adaptive spectral excision algorithm. (a) Original spectrum; (b) Low-quality spectra; (c) interference principle (physics); (d) High-quality spectra.

cosine trend is unclear and shows a distinct periodic trend, as shown by trum in Fig. 3(a), when the spectral signal quality is high, the interfer­
the red box. In contrast, high quality spectra retain the cosine trend at ence phenomena are strong and the difference between the mean values
the boundary between periods, preserving the thickness information. of the peaks and valleys of the corresponding cosine signal is significant.
However, low-quality spectra affected by secondary interference expe­ Therefore, we set up a loop to continuously update the interval shift
rience destructive interference between the thickness information they scale (changeScale) and calculate the maximum mean difference (Md)
carry and the secondary interference signal at the inter-periodic between peaks and valleys in each small interval, as well as the
boundary, submerging the cosine signal in this region, as shown by maximum mean difference (MD) between peaks and valleys over all
the principle model in Fig. 3(c). This phenomenon significantly in­ intervals. The ratio between Md and MD is used as a criterion to evaluate
terferes with the original spectral signal, resulting in a smaller maximum the spectral quality within the small intervals, as shown in Equation
frequency extracted in the VLA algorithm and consequently an under­ (13).
estimated thickness measurement result. (⃒ ⃒ )
max ⃒Mp − Mv ⃒, Md
To overcome this problem, we propose a novel adaptive spectral ⩾0.1 (13)
excision algorithm. The core idea of this algorithm is to create a movable MD
window, as indicated by the purple box in Fig. 3(b). We use the spectral In Equation (13), if the ratio between Md and MD is greater than or
quality within this window to determine the start and end points of the equal to 0.1, we consider the quality of the spectrum in this interval to be
excision. Specifically, we first create a moving window that divides the good. Therefore, the changeScale at this point represents the optimal
original spectrum into several small intervals. Within each interval, we starting position for spectral truncation. The final truncation scale value
calculate the mean peak value (Mp) and the mean valley value (Mv) to (Scale) can thus be expressed as:
assess the spectral quality. The window size is set to 5 % of the total
length of the original spectral signal. Within each small interval, Equa­ Scale = 0.1 × max(min(changeScale, 3.5), 0 ) (14)
tion (12) is used to calculate the mean peak value (Pi) and mean valley Since the original spectral signal is similar to a cosine function,
value (Vi) of the original spectral signal. where the frequency decreases as the wavelength increases, it is neces­
⎧ ∑min(|0.1×N×(changeScale+0.5)|,N− 1 ) sary to truncate symmetrically around the central wavelength when

⎪ i=max(|0.1×N×changeScale|,0 )
|Pi | performing spectral trimming. Consequently, the adaptive spectral

⎨ Mp =

Cp excision algorithm truncates an interval length proportional to the total
∑min(|0.1×N×(changeScale+0.5)|,N− 1 ) (12) length of the spectral signal at both the left and right ends. In Equation




⎩ i=max(|0.1×N×changeScale|,0 )
|V i | (14), the max and min functions limit the interval shift scale (change­
Mv =
Cv Scale) to the range (0, 3.5) to avoid truncation positions before the
leftmost side of the spectral signal and to ensure that the left and right
Where N represents the number of sample points in the original
truncation areas do not exceed 35 % of the spectral signal. The final
spectral signal, and changeScale ∈ (1, 9) denotes the change in the in­
truncation result is shown in Fig. 3(d).
terval shift scale so that the entire original spectral signal can be tra­
versed. Cp and Cv represent the number of peaks and troughs,
High-precision thickness extraction algorithm
respectively, in each small interval of the original spectral signal. The
To overcome the problem of secondary and multiple interferences
max and min functions ensure that the start point of the small interval is
caused by the peculiar two-layer structure of epi-wafers, we propose a
greater than 0 while ensuring that the endpoint does not exceed the total
high-precision thickness extraction algorithm that allows accurate
length of the spectral signal.
thickness extraction even when multiple peaks are present. As shown in
As can be seen from the high frequency region of the original spec­

5
J. Sun et al. Results in Physics 54 (2023) 107146

Fig. 4. High-precision thickness extraction algorithm. (a) Original periodogram; (b) Periodogram after noise reduction; (c) Calculate the sum of the energies; (d)
Extracted thickness results.

Fig. 4, this algorithm consists of three processes. The first process is the noise, the remaining peak sequences are expressed as Pi and Pj. The
pre-processing stage. After performing the time domain to frequency highest peak corresponds to Imax and the measurement precision
domain conversion using the VLA algorithm, the higher peaks in the threshold is represented by the term threshold. Several combinations of
periodogram represent the thickness information of the epi-wafer. peaks (Possibility[i, j]) can be identified following the peak selection
However, as shown in Fig. 4(a), there are also some weak lower peaks operation, which may potentially represent the final thickness. By
in the periodogram, which often represent noise introduced by external applying the constraint relation in Equation (17), the final thickness can
environmental factors during the measurement process. It is therefore be determined.
necessary to eliminate the frequency components that characterize this ( )
∑2
noise information. Equation (15) can be used to describe this noise maxIdx = argmaxi Ti [Possibility[i, j] ] (17)
reduction process. The effect of noise reduction is shown in Fig. 4(b). j=0




⎪ 1 ∑Z− 1 Where, Ti represents the vertical coordinate value of the power spectral

⎨ Ti , Ti ⩾Z i=0 Ti density of the i-th thickness index, denoting the amount of energy pre­
Ti = (15) sent. By summing up the total energy in all possible peak combinations,
⎪ ∑
⎪ 0, Ti ⩽ 1 Z− 1 Ti

⎪ we can determine the combination with the highest energy value

⎩ Z i=0
(maxIdx), which represents the final thickness result for the epi-wafer
sample.
Where Ti represents the vertical coordinate values of the periodogram
corresponding to the power spectral density for each thickness value. Z
represents the total number of coordinates in the periodogram, indi­ Overall procedure
cating the maximum measurement range. The noise reduction process
effectively eliminates weak peaks introduced by noise and maximizes Based on the proposed adaptive spectral excision algorithm, VLA
the preservation of peaks representing thickness information only. algorithm, and high-precision thickness extraction algorithm, the
Next, the situation needs to be discussed. In Case 1, it is assumed that semiconductor epi-wafer thickness detection process is shown in Fig. 5.
only three peaks remain in the periodogram after noise removal, as
illustrated in Fig. 4(d). The horizontal coordinates of these three peaks Experiments and results
from left to right indicate the thicknesses of the epitaxial layer, the
substrate, and their sum. In Case 2, it is assumed that after noise removal We conducted three experiments and implemented a comprehensive
the number of peaks in the periodogram exceeds three, as seen in Fig. 4 experimental design to confirm the practicability of the above-
(b). This indicates the presence of multiple interference phenomena and mentioned algorithms. In the subsequent trials, an infrared spectrom­
strong interference signals, which necessitates a peak selection opera­ eter with a central wavelength of 1050 nm, a bandwidth of 100 nm, and a
tion. The peak selection operation is defined by the constraint relation in resolution of 0.3 nm, supplied by Shanghai OceanHood Optoelectronics
Equation (16): Co., Ltd., was utilized. We used an SLED (Superluminescent Light
⎧ ⃒⃒ ⃒ Emitting Diode) infrared light source from Shenzhen Golight Company.
⎨ ⃒Pi + Imax − Pj ⃒⃒ < threshold It had a central wavelength of 1050 nm, a power of 20mW (3 dB), and a
⃒P + Pj − Imax ⃒ < threshold , i, j ∈ (0, Z − 1) (16) spectral width of 90 nm. In our study, we used eight sets of epi-wafers
⎩ ⃒⃒ i ⃒
Pj + Imax − Pi ⃒ < threshold with sapphire (AL2O3) substrates and GaN epitaxial layers provided
by Shanghai Fabxlab Semiconductor Co., Ltd. together. We enlisted the
where Z represents the maximum measurement range and is equal to the Sinoma Institute of Materials Research to measure the thickness of these
total number of data points in the periodogram. After removing the 8 sets of epi-wafer samples using a high-precision wide range

6
J. Sun et al. Results in Physics 54 (2023) 107146

Fig. 5. Scheme flowchart.

ellipsometer. According to the measurement results, the substrate follows: 31.06 μm, 27.13 μm, 38.51 μm, 79.49 μm, 40.16 μm, 34.92 μm,
thicknesses of the eight epi-wafer samples were as follows: 136.14 μm, 54.12 μm and 58.11 μm. As such, these measurements are used as ref­
222.39 μm, 278.05 μm, 311.28 μm, 342.73 μm, 477.38 μm, 531.69 μm, erences for the actual thickness of these epi-wafer samples.
and 620.50 μm. The epitaxial layer thicknesses of wafer samples as We conducted three experiments to verify the practicality of the

Fig. 6. Results of adaptive spectral excision experiment for 8 samples (in each subplot, the horizontal coordinate is the thickness of the sample and the vertical
coordinate is the power spectral density calculated from the periodogram; the left panel shows the results of the periodogram without the adaptive excision algorithm
and the right panel shows the results of the periodogram with the adaptive excision algorithm). (a)~(h):sample 1 ~ sample 8.

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J. Sun et al. Results in Physics 54 (2023) 107146

algorithm. In the experimental setup, we used a custom-built infrared strongly absorb infrared light. The algorithm can selectively remove
spectrometer from Shanghai OceanHood Optoelectronics Co., Ltd. The regions with poor interference quality and preserve those with high
spectrometer has a bandwidth of 120 nm, a center wavelength of 1020 interference quality, thereby ensuring the completeness and accuracy of
nm, a resolution of 0.3 nm, an integration time of 100 μs-30 min, and a crucial information in the spectrum.
signal-to-noise ratio of ≥2000:1. The light source used was a custom-
made SLED infrared light source from Shenzhen Golight Co., Ltd. The
center wavelength of the light source is 1020 nm, the band range is 960 VLA experiment
nm-1080 nm, and the power is 20mW (3 dB). The optical probe is our
independently developed achromatic focusing lens with a numerical Substrate thickness measurement
aperture of 0.1, a focal length of 40 mm and a measurement angle of ± We collected 50 reflection spectra for each sample’s substrate and
5◦ . The operating temperature of the entire measurement system is epitaxial layer at different times of the same day. We then calculated the
0℃–+45℃. thickness using different time-domain frequency-domain methods. We
used three time-domain frequency-domain transformation methods:
Fourier transform, Lomb-Scargle periodogram, and the VLA technique
Adaptive spectral excision experiment proposed in this paper. It is worth emphasizing that these three methods
are all based on FTIR technology and are all based on Equation (11) to
Silicon typically absorbs shorter wavelengths of infrared light but calculate the sample thickness, with their difference being the use of
has lower absorption rates for longer wavelengths. Therefore, the actual different methods to obtain fpeak in Equation (11). In Fig. 7, we plotted
collected reflection spectrum often exhibits weakened interference sig­ the thickness measurement results of the substrate using a box plot. It is
nals and poor interference quality in the short-wavelength region. In this not difficult to see that the VLA algorithm significantly improves both
experiment, we performed original spectral acquisition on eight epi- measurement accuracy and stability. We calculated the mean error and
wafer samples and compared the results of the Lomb-Scargle periodo­ variance of the results obtained by three different analysis methods and
grams with and without the adaptive removal algorithm, as shown in plotted them in the form of a histogram, as shown in Fig. 8.
Fig. 6. Each small graph in the figure represents one epi-wafer sample, Analyzing Measurement Precision: (1) Comparing the results of FFT
where the left graph shows the periodogram obtained directly from the with those of the LSP method, the measurement precision using the FFT
original spectra, while the right graph shows the periodogram after approach is 98.86 %, while using the LSP algorithm alone, the mea­
applying the adaptive removal algorithm. The true values of substrate surement precision is 99.67 %, indicating a significant enhancement in
thickness, epitaxial layer thickness, and their sum have been plotted at measurement accuracy. Hence, it can be demonstrated that employing
the corresponding peaks in the right plot. the Lomb-Scargle periodogram during the time-domain to frequency-
Upon examining Fig. 6, it becomes apparent that the Lomb-Scargle domain transformation of the original spectrum is a more promising
periodogram with the adaptive spectral excision algorithm produces technique. (2) Comparing the results of the LSP algorithm alone with
clearer and more concentrated frequency peaks for each sample, with those of the VLA, the measurement precision when using the LSP algo­
less interference between adjacent peaks. In contrast, the periodogram rithm alone is 99.67 %, whereas it reaches 99.94 % with the VLA al­
without the adaptive spectral excision algorithm displays greater noise gorithm. This demonstrates that combining the VMD algorithm with the
and mixed signals. This demonstrates that the adaptive excision algo­ LSP algorithm can mitigate the impact of uneven light source power
rithm can effectively deal with weak interference signals and poor distribution, further improving measurement precision. Analyzing
interference quality resulting in problems from certain epi-wafers that measurement stability, the results show that using the LSP algorithm

Fig. 7. Box plots of experimental results of thickness measurements of the substrate (in each subplot, the left box corresponds to the results obtained through the FFT
method, the middle box to those obtained using the Lomb-Scargle periodogram method, and the right box to the results analyzed with the VLA algorithm proposed in
this paper). (a)~(h):sample 1 ~ sample 8.

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J. Sun et al. Results in Physics 54 (2023) 107146

Fig. 8. Data analysis of substrate thickness measurement experiments. (a) mean value error; (b) variance (statistics).

alone results in an approximately 55 % increase in measurement sta­ Fig. 11 shows the residual peak plots of the periodograms of the eight
bility when compared to using the FFT. Similarly, the VLA algorithm epi-wafer samples after noise removal, together with the corresponding
leads to a roughly 35 % increase in measurement stability when coordinates of each peak point. The x-axis depicts the thickness indices
compared to using the LSP algorithm alone. in the given range, while the y-axis depicts the energy or power spectral
density for each thickness index. The traditional thickness extraction
Epitaxial layer thickness measurement method usually extracts peaks based on their height and left-to-right
We conducted thickness measurements on the epitaxial layer using order. Simply put, the traditional method identifies the three highest
identical criteria to the substrate experiment. The experimental findings peaks as follows: the peak with the smallest horizontal coordinate is
corresponded significantly, as illustrated in Figs. 9 and 10. considered the epitaxial layer thickness, followed by the substrate
thickness, and the peak with the largest horizontal coordinate is the sum
of the two. Table 1 displays the thickness extraction results of both the
Thickness extraction experiment traditional method and the proposed method. An observation reveals,
for the eight epi-wafer samples tested in this investigation, that the
In this experiment, instead of focusing only on the substrate or traditional thickness extraction method lacks the required accuracy for
epitaxial layer of the epi-wafer samples, we perform thickness mea­ industrial production. Significant deviations are evident in the thickness
surements on the entire epi-wafer sample to obtain the substrate thick­ results of samples 1, 2, 4, 5, and 6.
ness and epitaxial layer thickness simultaneously. To validate the Subsequently, we employed a dot plot to illustrate the measurements
accuracy of the high-precision thickness extraction algorithm, we of the two thickness extraction methods alongside the reference thick­
compare the results of the traditional thickness extraction method with ness of the sample, as depicted in Fig. 12. In the figure, the solid gray line
the results of the proposed high-precision thickness extraction represents the results obtained using the conventional thickness
algorithm.

Fig. 9. Box plots of experimental results of thickness measurements of the epitaxial layer (in each subplot, the left box corresponds to the results obtained through
the FFT method, the middle box to those obtained using the Lomb-Scargle periodogram method, and the right box to the results analyzed with the VLA algorithm
proposed in this paper). (a)~(h):sample 1 ~ sample 8.

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J. Sun et al. Results in Physics 54 (2023) 107146

Fig. 10. Data analysis of epitaxial layer thickness measurement experiments. (a) mean value error; (b) variance (statistics).

Fig. 11. Remaining peaks after applying the denoising algorithm in section 2.3.2 to the Lomb-Scargle periodogram (each peak represents a thickness value and the
horizontal and vertical coordinates of the peak point have been labelled, where the horizontal coordinate is the thickness value corresponding to that point and the
vertical coordinate is the power spectral density corresponding to that thickness). (a)~(h): sample1 ~ sample8.

Table 1
Comparison of the results of different thickness extraction algorithms (the traditional method uses the thickness extraction method based on peak height and order as
described above; the new method uses the high-precision thickness extraction algorithm proposed in this paper).
Sample number Epitaxial thickness(μm) Substrate thickness(μm)

Traditional method New method Reference thickness Traditional method New method Reference thickness

1 31.06 30.91 31.06 64.11 135.89 136.14


2 11.17 26.87 27.13 26.87 222.07 222.39
3 38.28 38.28 38.51 277.86 277.86 278.05
4 79.35 79.35 79.49 152.51 310.92 311.28
5 37.80 40.01 40.16 40.01 342.59 342.73
6 34.68 34.68 34.92 51.71 477.51 477.38
7 53.81 53.81 54.12 531.57 531.57 531.69
8 57.94 57.94 58.11 620.73 620.73 620.50

Fig. 12. Thickness extraction results using different methods. (a) substrate; (b) epitaxial.

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J. Sun et al. Results in Physics 54 (2023) 107146

extraction method, while the solid blue line represents the outcomes refractive index of 1, the range extends from 6 μm to 1600 μm and
derived from the precision thickness extraction method introduced in beyond.
this study. The red dashed line represents the reference thickness of the The VMD decomposition technique is an advanced method for
sample. It becomes evident that, whether for the substrate or the decomposing signals, and its decomposition performance is highly
epitaxial layer, the results obtained using the precision thickness influenced by the parameter settings. We found through extensive
extraction algorithm presented in this study closely approximate the experimentation that a larger value of the parameter α results in
reference thickness. Furthermore, it is discernible that, in comparison to smoother low-frequency Imf1 signals, as shown in Equation (9). In our
the substrate, the results for the epitaxial layer are more precise. This method, Imf1 represents the baseline signal of a light source when K is set
discrepancy arises due to the relatively greater thickness of the sub­ to 2. If the value of the parameter α is small, the Imf1 signal exhibits
strate, which is positioned beneath the epitaxial layer, resulting in a slight cosine trends and retains some frequency information. In some
weaker intensity of light beams reflected from the upper and lower cases, the intensity of the noise signal surpasses that of the thickness
surfaces of the substrate. Consequently, portions of the reflection spec­ signal, making it difficult to determine whether the frequency compo­
trum that convey information about the substrate thickness are more nents carried by the Imf1 signal when α is reduced represent noise or
susceptible to interference from multiple reflected signals, making the thickness information. Thus, determining the parameter α has an impact
accurate extraction of peak points challenging after the time-domain to on the accuracy of the final measurement results. In this study, we set
frequency-domain transformation. However, the employment of the the parameter to 3000 based on experimental experience, but the ac­
precision thickness extraction algorithm introduced in this study effec­ curate determination of parameter α through spectral quality or infrared
tively mitigates this issue. source parameters is possible. This is also the main focus of our future
research.
Discussion Furthermore, the VMD decomposition technique introduces errors in
the reconstructed Imf components’ center frequency and bandwidth
This study proposes a potentially effective method for achieving compared to the original spectrum signal. Although these errors have no
high-precision measurements of substrate and epitaxial layer thickness impact on the current measurement accuracy, we believe a previously
in semiconductor epi-wafers. Nevertheless, there are still some unre­ suggested EMD decomposition method can prevent such a situation. The
solved issues that require discussion. principles of the completely data-driven EMD decomposition technique,
During the computation of the Lomb-Scargle periodogram, a stride, which does not require any signal reconstruction process, have been
also known as the frequency range and designated as f in Equation (6), extensively studied. However, the EMD decomposition method was not
must be set manually. The Lomb-Scargle periodogram operates by chosen because it cannot control the number of decomposed modes, i.e.
nonlinearly fitting the raw data over a specified interval provided by the the K-value in the VMD algorithm. As a result, the EMD method may
user. Thus, the determination of f, the frequency range, establishes the decompose the substrate and epitaxial layer thickness into different
measurement accuracy of the outcome. Practical measurement needs to modes or place them within the same mode when decomposing the
guide the selection of f to guarantee both efficient and precise outcomes. original spectrum. This depends solely on the intensity of the noise
It is necessary to discuss the capabilities of this device. Firstly, the interference signal. However, it is believed that for the measurement of
device uses near-infrared light as its light source. Therefore, the device is single-layer thin films, the EMD decomposition method provides better
only suitable for testing thin film materials that can be penetrated by results. This is because only the calculation of the Lomb-Scargle perio­
near-infrared light, such as most semiconductor materials and insulating dogram for the Imf1 component is required. Single-layer thin films do not
materials. For most metal materials, we believe that a UV light source exhibit secondary interference phenomena, and the quality of interfer­
with stronger penetration power is needed. Secondly, the device ence between reflected and transmitted light is good, with thickness
currently only applies to double-layer thin films, that is, measuring the information necessarily present in the high-frequency component Imf1.
thickness of both the substrate and the single-layer epitaxial layer However, for the double-layer epi-wafer samples used in this study, the
simultaneously. We will continue to improve and optimize the algorithm VMD method is more appropriate.
to make it suitable for measuring the thickness of multi-layer thin films This study conducted two denoising processes, which will be
in the future. Finally, it is also necessary to discuss the range of this explained for clarity. The initial denoising process involves setting the
device. (1) Upper Thickness Limit: The maximum thickness that can be VMD decomposition modal number, K, to 2 during the VLA algorithm.
measured is determined by hardware parameters, such as the spec­ Setting K to 2 corresponds to Imf1 representing the slowly changing part
trometer and light source used. The light source used covers a wave­ of the signal characterized by low-frequency vibrations and long-term
length range of 960 nm to 1080 nm, with a spectral width of 120 nm. The trends. Imf1 was discarded, and only the Lomb-Scargle periodogram
resolution of the spectrometer is 0.3 nm. Therefore, under optimal calculation for Imf2 was performed to eliminate a fraction of the weak
conditions, the reflection spectrum collected comprises 400 sampling noise signal. However, this alone is insufficient for achieving the final
points. Following the Nyquist sampling theorem, a minimum of two thickness extraction. Thus, a second noise removal process is included in
sampling points is required to accurately reconstruct one cycle. Conse­ the high-precision thickness extraction algorithm. This process is per­
quently, with 400 sampling points, up to 200 cycles may be restored. For formed through Equation (15). The second noise removal process is
the wavelength range of 960 nm to 1080 nm, computer-simulated capable of removing most of the noise in the original spectra, thereby
reflection spectra imply that an 800 μm thickness (n = 2) corresponds reducing computational time for the subsequent thickness extraction
to a reflection spectrum with 200 cycles. Therefore, the upper thickness process and improving efficiency and accuracy. The interplay of these
limit for measuring thin film materials with a refractive index of 2 is 800 two noise removal processes resulted in more accurate and stable
μm. (2) It is important to note the lower thickness limit. The FTIR thickness extraction.
method computes thickness based on frequency, and thus, the reflection
spectrum should cover at least one cycle for frequency calculation to be Conclusion
possible. Simulated reflection spectra between the wavelengths of 960
nm and 1080 nm indicate that a reflection spectrum with a single cycle In this paper, we present a highly accurate method for measuring the
corresponds to a thickness of approximately 3 μm. Therefore, the lower thickness of a semiconductor epi-wafer using Fourier infrared interfer­
thickness limit for thin film materials with a refractive index of 2 is 3 μm. ometry. The proposed method uses the VLA algorithm, which carries out
To summarize, the measurement range of this system for thin film ma­ VMD decomposition and Lomb-Scargle periodogram calculation on the
terials with a refractive index of 2 spans from 3 μm to 800 μm. By original spectrum. Through this, we can obtain frequency components
following the relationship in Equation (11), it is apparent that for a that represent the thicknesses of both the epi-wafer substrate and

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J. Sun et al. Results in Physics 54 (2023) 107146

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