CROSS-REFERENCE TO RELATED APPLICATION

[00911 The present application claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Application Serial Number 62/693,573, filed July 3, 2018, entitled Dual interferometry Wafer Thickness Gauge, naming Avner Safrani as inventor, which is incorporated herein by reference in the entirety.

TECHNICAL FIELD

[00021 The present disclosure relates generally to sample thickness measurements and , more particularly, to interferometric sample thickness measurements.

BACKGROU D

[00933 Accurate measurements of the absolute thickness of thin samples such as, but not limited to, semiconductor wafers are widely useful, particularly in semiconductor fabrication and metrology. For example, high-resolution thickness measurements of samples ma be used to determine the strain associated with fabricated features on a sample, which may be indicative of potential defects. By way of another example, certain tools such as, but not limited to. X-ray metrology tools, have relatively slow focusing mechanisms such that accurate measurements of sample thickness ma facilitate efficient alignment of the sample. Further, it is generally desirable to provide thickness measurement techniques that may be broadly applied to a wide variety of samples including patterned and unpatterned samples or samples having a wide variety of physical, opticai, or mechanical properties. Additionally, approaches to thickness measurements must be balanced against increases in cost, system complexity, and system reliability St may therefore be desirable to develop system and methods for accurate and efficient thickness measurements. SUMMARY 0004j A system is disclosed in accordance with one or more illustrative embodiments of the present disclosure. In one illustrative embodi ent, the syste includes a controller communicatively coupled to a first interferometer and a second interferometer in another illustrative embodiment, the controller receives a first interference signal from the first interferometer, where the first interferometer generates a first interferogram between a first surface of a test sample and a first surface of a reference sample having a known thickness with a first illumination bea as at least one of the test sample or the reference sample is scanned along a measurement direction. For example, the first Illumination beam may include a first portion of an illumination beam from a beamsplitter. In another illustrative embodiment, the controller receives a second interference signal from the secon interferometer, where the second interferometer generates a secon interferogra between a second surface of the test sample and a second surface of the reference sample with a second illumination beam. For example, the second illumination beam may include a second portion of the illumination beam from the beamsplitter. In another illustrative embodiment, the controller determines a thickness of the test sample along the measurement direction based on the thickness of the reference sample and a distance travelled by the translation stage between peaks of envelopes of the first and second interference signals, iooasi A system is disclosed in accordance with one or more illustrative embodiments of the present disclosure. In one illustrative embodiment, the system includes an illumination source. In another illustrative embodiment, the system includes a beam splitter configured to split illumination from the illumination source into a first illumination beam and a second illumination beam:. In another illustrative embodiment, the system includes a translation stage configured to linearly translate a reference sample along a measurement direction, where the reference sample has a known thickness in another illustrative embodiment, the system includes a first interferometer configured to generate a first interferogram between a first surface of a test sample and a first surface of the reference sample with the first illumination beam. In another illustrative embodiment, the system includes a second interferometer configured to generate a second interferogra between a second surface of the test sample and a second surface of the reference sample with the second illumination beam. In another illustrative embodiment the system includes a controller communicatively coupled to the first and second interferometers. In another illustrative embodiment, the controller receives first and second interference signals from the first and second interferometers including interference fringe strengths of the first and second interferograms as the translation stage scans the reference sample along the measurement direction. In another illustrative embodiment, the controller determines a thickness of the test sample along the measurement direction based on the thickness of the reference sample and a distance travelled by the translation stage between peaks of envelopes of the first and second interference signals.

|0006| A method is disclosed in accordance with one or more illustrative embodiments of the present disclosure. In one illustrative embodiment, the method includes scanning at least one of a test sample or a reference sample having a known thickness along a measurement direction. In another illustrative embodiment, the method includes receiving a first interference signal from a first interferometer associated with a first interferogram between a first surface of the test sample and a first surface of the reference sample with a first illumination beam, where the first illumination beam includes a first portion of an illumination bea from a beamsplitter. In accordance with one or more illustrative embodiments of the present disclosure, the method includes receiving a second interference signal from the second interferometer associated with a second interferogram between a second surface of the test sample and a second surface of the reference sample with a second illumination beam, where the second illumination beam includes a second portion of the illumination beam from the beamsplitter. In accordance with one or more illustrative embodiments of the present disclosure, the method includes determining a thickness of the test sample along the measurement direction based on the thickness of the reference sample and a distance travelled by the translation stage between peaks of envelopes of the first and second interference signals.

[0007J it s to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not necessarily restrictive of the invention as claimed. The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and together with the general description, serve to explain the principles of the invention.

BRIEF DESCRIPTION OF DRAWINGS

£0008} The numerous advantages of the disclosure may be better understood by those skilled in the art by reference to the accompanying figures in which:

FIG. 1A is a conceptual view of a dual-interferometer sample thickness gauge, in accordance with one or more embodiments of the present disclosure;

FIG 1 B is a conceptual view of the sample thickness gauge arranged to focus the source beam to a diffraction-limited spot size on the test sample and the reference sample, in accordance with one or more embodiments of the present disclosure;

FIG 1C is a conceptual view illustrating a sample thickness gauge including a mirror in a reference ar but not in the sample arm of the first interferometer, but including a mirror in a sample arm but not in the second interferometer, in accordance with one or more embodiments of the present disclosure;

FIG 2A is a flow diagram illustrating steps performed in a method for measuring thickness based on dual Interferometry, in accordance with one or more embodiments of the present disclosure;

FIG. 2B is a flow diagram illustrating sub-steps for determining the thickness of the test sample based on the peak separation distance and the thickness of the reference sample, in accordance with one or more embodiments of the present disclosure;

FIG 2C is a flow diagram illustrating sub-steps for determining envelopes of the first and second interference signals using digital signal processing techniques, in accordance with one or more embodiments of the present disclosure;

FIG. 3 is a conceptual view of the sample arm and reference arm of each interferometer, in accordance with one or more embodiments of the present disclosure;

FIG 4A Is a plot of a sampled interference signal, a reconstructed interferenc signal, an envelope of the reconstructed interference signal, and a simulated Gaussian envelope, in accordance with one or more embodiments of the present disclosure; FIG. 4B is a plot of sampled first and second interference signals, reconstructed first and second interference signals, envelopes of the first and second reconstructed signals, and Gaussian envelopes for the first and second interference fringes associated with the first and second interferometers, in accordance with one or more embodiments of the present disclosure;

FIG. 5 includes spatially-resolved dual interferometry thickness measurements of samples having step features with heights verified by atomic force microscopy, in accordance with one or more embodiments of the present disclosure; and

FIG. 6 is a p!ot illustrating 30 repeated measurements of a 300 m sample wafer having a nominal thickness of 776 pm, in accordance with one or more embodiments of the present disclosure.

DETAILED DESCRIPTION 0089 Reference will now be made in detail to the subject matter disclosed, which is illustrated in the accompanying drawings. The present disclosure has been particularly shown and described with respect to certain embodiments and specific features thereof. The embodiments set forth herein are taken to be illustrative rather than limiting. It should be readily apparent to those of ordinary skill in the art that various changes and modifications in form and detail may be made without departing from the spirit and scope of the disclosure

J00101 Embodiments of the present disclosure are directed to systems and methods for measuring the absolute thickness of a sample using dual interferometers and a common reference sample. A dual-interferometer thickness measurement system as described herein may include two interferometers arranged to generate interferograms between opposing sides of a test sample and opposing sides of a reference sample having two opposing optically-polished surfaces and a known thickness. For example, a first interferometer may generate an interferogram between a first surface of the test sample and a first surface of the reference sample, and a second interferometer may generate an interferogram between a second surface of the test sample and a second surface of the reference sample. A dual-interferometer thickness measurement system may further include a Sow-coherence optica! light source such as, but not limited to, a broadband laser source such that the interferometers generate interference fringes only when arms of the interferometers are matched within a limited range based on the coherence length of the light source. In particular, an envelope function (e.g., a fringe envelope) associated with a strength of interference fringes may exhibit a peak when the arms of an interferometer are matched and may diminish as the length difference between the arms of the interferometer exceeds the coherence length in either direction. toon] in some embodiments, an absolute thickness measurement of the test sample is generated by translating either the test or the reference sample along the measurement direction and determining the absolute thickness of the test sample based on a translation distance of the translated sample between peaks of the fringe envelopes of the two Interferometers (e.g., a peak separation distance) and the known sample thickness.

[00123 The systems and methods may provide thickness measurements for a single location on the test sample or an expanded area on the test sample depending on the illumination conditions and the type of detector used. In some embodiments, the light source is focused to opposing spots on the test and reference samples. Accordingly, each interferometer may include a single-pixel detector to capture fringe strength associated with the illuminated locations. In some embodiments, the light source is collimated or otherwise directed to opposing extended areas on the test and reference samples. Accordingly, each interferometer may include a mu!ti-pixei detector to simultaneously capture fringe strength associated with a plurality of spots in the illumination areas. In this regard, a two-dimensional thickness map within the illuminated areas may be captured in a single measurement.

[0O133 li Is recognize herein that dual-interferometry thickness measurements described herein may provide highly accurate and efficient thickness measurements.

[0014] For example, the use of two interferometers to simultaneousl generate interferograms between opposing sides of test and reference samples provides excellent synchronization between the two Interferograms with a linear relationshi between the peak separation distance an the test sample thickness, thus enabling highly accurate d measurements. Further, the measurement repeatability may be based on the repeatability of the translation and sampling systems rather than position errors of reference components. When simultaneously generating dual interferograms based on a single linear scan, measurement repeatability may be based on the repeatability of a linear encoder in the translation system. For instance, current encoder systems may provide, but are not limited to, a repeatability of +/- 1 nm.

|00isi Additionally, since the measurement is differential, the scanning distance for which the entire system needs to be stable is relatively small such that most mechanical parts are suitable for operation with minimal system-generated noise. For instance, the thickness of a 300 semiconductor wafers typically varies between 750 and 850 pm such that a thickness measurement with an 800 n reference sample would require stable operation over a range of approximately 50 pm. With a translation speed of 250 mm/s as a noniimiting example, the temporal stability Is only approximately 200 ps,

|0016| By way of another example, dual-interferometry thickness measurements described herein may be suitable for thickness measurements of a broad range of samples with varying optical, physical, or mechanical properties including patterned or unpatterned surfaces. For instance, the tight source may be selected or tuned to provide a desired spectrum corresponding to the reflectance of test samples to be measured. Further, the impact of film layers on a sample on interferograms may be well understood and taken into account when performing thickness measurements. iooiTj FIG. 1 A is a conceptual view of a dual-interferometer sample thickness gauge 100, in accordance with one or more embodiments of the present disclosure. 00183 lc one embodiment, the sample thickness gauge 100 includes a light source 102 to generate a source beam 104 having a limited or known temporal coherence length in this regard, the light source 102 may be a low-coherence source, a partially-coherent source, or the like. In another embodiment, the sample thickness gauge 100 includes a source beam splitter 108 to split the source beam 104 such that portions of the source beam 104 may be directed to the interferometers 108. The source beam splitter 108 may include any type of beamsplitter known in the art including, but not limited to, a fiber- based beamsplitter, a cube beamsplitter, or a piate beamsplitter .

[0019] in another embodiment, the sample thickness gauge 100 includes two interferometers 108 (e.g., interferometers 108a and 108b) arranged to generate interferograms based on reflections from opposing surfaces of a test sample 1 10 and a reference sample 1 12. Further, the reference sample 1 12 may include two opposing optically smooth surfaces with a known or calibrated thickness along the measurement direction 120.

[0020] For example, as illustrated in FiG. 1A, a first interferometer 108a may generate an interferogram between a first test surface 1 14a of the test sample 1 10 and a first reference surface 116a of the reference sample 1 12, while a second interferometer 108b may generate an interferogram between a second test surface 1 14b of the test sample 110 and a second reference surface 116b of the reference sample 1 12.

[0021] In another embodiment, the sample thickness gauge 100 includes at least one linear translation stage 118 for translating at least one of the reference sample 1 12 or the test sample 110 along a measurement direction 120 (e.g., a direction along which thickness of the test sample 1 10 is to be measured). For example, FSG 1A illustrates a linear translation stage 118 positioned to translate the reference sample 1 12 along the measurement direction 120 However, though not shown, the sample thickness gauge 100 may include a linear translation stage 118 to translate the test sample 1 10. Further, the sample thickness gauge 100 may include two linear translation stages 1 18 to position both the reference sample 112 and the test sample 1 10.

[00223 ia another embodiment, the sample thickness gauge 100 includes a controller 122. in another embodiment, the controller 122 includes one or more processors 124 configured to execute program instructions maintained on a memory medium 126 (e.g., memory) in this regard, the one or more processors 124 of controller 122 may execute any of the various process steps described throughout the present disclosure. [0023J The one or more processors 124 of a controller 122 may include any processing element known in the art. In this sense, the one or more processors 124 may include any microprocessor-type device configured to execute algorithms and/or instructions. In one embodiment, the one or more processors 124 may consist of a desktop computer, mainframe computer system, workstation, image computer, parallel processor, or any other computer system (e.g,, networked computer) configured to execute a program configured to operate the sample thickness gauge 100, as described throughout the present disclosure. It is further recognized that the term“processor” may be broadly defined to encompass any device having one or more processing elements, which execute program instructions from a non-transitory memory medium 126.

[00243 The memory medium 126 may include any storage medium known in the art suitable for storing program instructions executable by the associated one or more processors 124. Further, the memory medium 126 may store any type of data for use by any component of the sample thickness gauge 100 such as, but not limited to, inierferograms generated by the interferometers 108. For example, the memory medium 126 may include a non-transitory memory medium. By way of another example, the memory mediu 126 may include, but is not limited to, a read-only memory, a random- access memory, a magnetic or optical memory device (e.g., disk), a magnetic tape, a solid-state drive and the like. It is further noted that memory medium 126 may be housed in a common controller housing with the one or more processors 124. In one embodiment, the memory medium 126 may be located remotely with respect to the physical location of the one or more processors 124 and controller 122. For instance, the one or more processors 124 of controller 122 may access a remote memory (e.g., server), accessible through a network (e.g., internet, Intranet and the like). Therefore, the above description should not be interpreted as a limitation on the present invention but merely an illustration.

[O02SJ Additionally, the controller 122 and any associated components (e.g., the processors 124, the memory medium 126, or the like) may include one or more controllers housed in a common housing or within multiple housings. Further, the controller 122 may be integrated with and/or perform the functions of any components in the sample thickness gauge 100.

[0026] in another embodiment, the controller 122 includes at least one analog to digital converter 128 to sample and digitize analog signals from the interferometers 108 associated with the interferograms. Further, the analog to digital converter 128 may sample signals using any technique. For example, the analog to digital converter 128 may sample signals at defined intervals based on an internal clock. By way of another example, the analog to digital converter 128 may sample signals based on a trigger signal. In one embodiment, the linear translation stage 1 18 provides a hardware position trigger at selected position intervals to the analog to digital converter 128 to provide sampling at selected locations of the linear translation stage 1 18.

[0027J The controller 122 may perform any number of processing or analysis steps disclosed herein including, but not limited to, receiving interferograms from the interferometers 108, analyzing the interferograms, or performing thickness measurements of the test sample 110 based on the interferograms. Further, the controller 122 may employ any number of algorithms, process flows, or the like.

I002S3 Referring now generally to FIGS, 1A through 10, various components of the sample thickness gauge 100 will be described in greater detail.

[0029] The light source 102 may include any type of light source known in the art suitable for providing a source beam 104 having a limited or otherwise known coherence length. It is recognized herein that a signal strength of interference fringes between the test sample 110 and the reference sample 112 in each of the interferometers 108 will peak when arms of the interferometers 108 have equal lengths. Further, the signal strength of the interference fringes will drop off as the optica! path length difference between the arms of the interferometers 108 exceeds the temporai coherence iength of the source beam 104. The signal strength of interference fringes from each of the interferometers 108 may thus be characterized by envelope functions having peaks where the optical path Iength difference between the arms of the interferometers 108 are matched and having a half- width related to the temporal coherence length of the source beam 104. Accordingly, the to temporal coherence length of the source beam 104 may be selected to provide a desired envelope width.

[0030] in one embodiment, the Sight source 102 is a laser source. For example, the light source 102 may include one or more broadband lasers such as, but not limited to, one or more supercontinuum lasers or white-light lasers. By way of another example, the light source 102 may include one or more superluminescence laser diodes (SIDs). In another embodiment, the light source 102 indudes one or more Sight emitting diodes (LEDs) in another embodiment, the light source 102 includes a lamp source such as, but not limited to, an arc lamp, a discharge lamp, an eiectrode-iess lamp, or the like.

[0031] Further, the light source 102 may provide the source beam 104 using any technique. For example, the light source 102 may provide the source beam 104 through an optica! fiber. By way of another example, the light source 102 may provide the source beam 104 as a free-space beam.

[0032] The light source 102 may provide a source beam 104 having any wavelength or range of wavelengths. Further, the spectrum of the source beam 104 may be selected based on optica! properties (e.g , absorption, reflectivity, transmittivity, or the like) of a sample to be characterized it is further recognized herein that the spectral width of the source beam 104 may be inversely related to the temporai coherence length such that increasing the spectral width of the source beam 104 may decrease the temporal coherence length and vice versa.

[0033] In on© embodiment, the sample thickness gauge 100 indudes two or more light sources 102 having different spectra that may be selectively utilized. In another embodiment, the light source 102 may include a tunable Sight source 102 to provide a source beam 104 having tunable spectrum. In another embodiment, the sample thickness gauge 100 includes one or more spectral filters (e.g., tunable spectral filters, a series of selectable fixed spectral filters, or the like) to control the spectrum of the source beam 104. 0034J The interferometers 108 may include any type of interferometers known in the art suitable for generating interference fringes between the test sample 110 and the reference sample 1 12 including, but not limited to, a ichelson interferometer or a Linnik interferometer. Further, the interferometers 108 may project or focus the source beam 104 on the test sample 1 10 or the reference sample 1 12 to any desired spot size.

[003S| In one embodiment, each interferometer 108 Includes a beamsplitter 130 configured to split the respective source beam 104 into two arms, with a sample arm 132 (e.g., sample arms 132a, 132b) including the test sample 110 and a reference arm 134 (e.g , reference arms 134a, 134b) directed to the reference sample 112. In another embodiment, each interferometer 108 includes a detector 136 configured to receive the combined reflected signal from the two arms. In this regard, the intensity of light on the detector 136 may vary based on interference between the test surface 114 and the reference surface 1 16.

100361 Each interferometer 108 may include any type of detector 136 known in the art. In one embodiment, the detector 136 may include at least one single-pixel detector such as, but not limited to, a photodiode, an avalanche photodiode, or the like in another embodiment, the detector 136 may include at least one multi-pixel detector such as, but not limited to, a complementary metal-oxide-semlconductor (CMOS) device or a charge- coupled device (CCD). In this regard, the detector 136 may generate a two-dimensional interferogram associated with an extended illuminated region of the test sample 1 10 in which the intensity of light at each pixel corresponds to a different portion of the test sample 1 10. Further, two-dimensional interferograms may be used to determine thickness variations of the test sample 110 across the extended illuminated region.

|003Tl In anothe embodiment, each detector 136 is connected to the controller 122 (e.g., the analog to digital converter 128 of the contrail er 122) such that the controller 122 may receive signals generated by the detector 136.

[00383 The sample thickness gauge 100 may further include one or more additional optical components to direct and/or modify the source beam 104 such as, but not limited to, turning mirrors (e.g., mirrors 138), lenses, intensity filters, or spectral filters. [0039] FIG. †B is a conceptual view of the sample thickness gauge 100 arranged to focus the source beam 104 to a diffraction-limited spot size on the test sample 1 10 and the reference sample 1 12, in accordance with one or more embodiments of the present disclosure. In this regard, the sample thickness gauge 100 may determine a thickness of the test sample 110 at a localized point 140.

[0040] In one embodiment, the sample thickness gauge 100 includes a fiber-based Sight source 102 coupled to a fiber-based source beam splitter 106. In this regard, each interferometer 108 may receive a portion of the source beam 104 through a fiber 142.

[0041] in another embodiment, the source beam 104 from the fiber 142 is split by the beamsplitter 130 into a sample arm 132 and a reference arm 134.

[0042] In another embodiment, at least one interferometer 108 includes one or more focusing elements 144 (e.g., lenses, curved mirrors, or the like) to collect the source beam 104 from the fiber 142 and direct the source beam 104 to the test sample 1 10 and the reference sample 112. Further, the one or more focusing elements 144 may be located prior to the beamsplitter 130, in the sample arm 132, in the reference arm 134, or any combination thereof.

[O043] In one embodiment, as illustrated in FIG. 1 B, the focusing elements 144 focus the source beam 104 onto the test sample 1 10 and the reference sample 1 12 (e.g., to a diffraction-limited spot) in another embodiment, though not shown, the focusing elements 144 collimate the source beam 104 to illuminate extended regions of the test sample 1 10 and the reference sample 112.

[0044] It is recognized herein that focusing the source beam 104 on the test sample 1 10 and reference sample 112 may provide greater tolerance for mis-!eveiing of the test sample 1 10 or the reference sample 1 12 relative to illuminating extended areas, whereas extended illumination with the source beam 104 may provide extended thickness measurements in a single shot (e.g., to measure variations of the test sample 110, fabricated features on the test sample 110, or the like). In another embodiment, the focusing elements 144 are adjustable or removable such that the focusing conditions may be adjusted or otherwise selected. For example, an interferometer 108 may include removable objective lenses to selectively switch between focused and extended illumination. By way of another example, an interferometer 108 may include adjustable Senses (e.g., lenses having adjustable powers, lenses on translation stages, or the like) to selectively switch between focused and extended illumination.

|O04§3 In another embodiment, at least one Interferometer 108 includes one or more optical condensers 148 to direct and/or focus combined light from the test sample 1 10 and the reference sample 112 to the detector 136.

|D046] Further, it is not necessarily the case that the first and second interferometers 108a, 108b have the same components in the respective arms as illustrated in FIGS. 1A and 1 B. FIG. 1 C is a conceptual view illustrating a sample thickness gauge 100 including a mirror 148 in a reference arm 134 but not in the sample arm 132 of the first interferometer 108a, but including a mirror 148 in a sample arm 132 but not in the second interferometer 108b, in accordance with one or more embodiments of the present disclosure. In the configuration of the sample thickness gauge 100 illustrated in FIG. 1C, a portion of the source beam 104 in the reference arm 134 propagates through the beamsplitter 130 and is incident on the reference surface 1 16, whereas a portion of the source beam 104 in the sample arm 132 is reflected by the beamsplitter 130 and directed to the test sample 1 10 by a mirror 148.

|0047| Referring now to FIGA. 2A through 2C, various steps for measuring thickness based on dual interferometry is described in greater detail.

100483 FIG. 2A is a flow diagram illustrating steps performed in a method 200 for measuring thickness based on dual interferometry, in accordance with one or more embodiments of the present disclosure. Applicant notes that the embodiments and enabling technologies described previously herein in the context of the sample thickness gauge 100 should be interpreted to extend to the method 200. It is further noted, however, that the method 200 is not limited to the architecture of the sample thickness gauge 100, [0049] in one embodiment, the method 200 includes a step 202 of scanning at least one of the test sample 110 or the reference sample 112 along a measurement direction 120. in another embodiment, the method 200 includes a step 204 of receiving interference signals from a first interferometer 108a associated with a first interferogram between a first test surface 1 14a of the test sample 110 and a first reference surface 116a of the reference sample 1 12 during the scan. In another embodiment, the method 200 includes a step 206 of receiving interference signals from a second Interferometer 108b associated with a second interferogram between a second test surface 1 14b of the test sample 1 10 and a second reference surface 116b of the reference sample 1 12 during the scan. In another embodiment, the method 200 includes a step 208 of determining a thickness of the test sample 1 10 along the measurement direction 120 based on a known thicknes of the reference sample 1 12 and a distance travelled by the translation stage between peaks of envelopes of the first and second interference signals.

[00503 As described previously herein, a signal strength of interference fringes between the test sample 110 and the reference sample 1 12 in each of the interferometers 108 wi!i peak when arms of the interferometers 108 have equal lengths. Further, the signal strength of the interference fringes will drop off as the optical path length difference between the arms of the interferometers 108 exceeds the temporal coherence length of the source beam 104. Accordingly, scanning the reference sample 1 12 may simultaneously generate interference fringes from the first interferometer 108a that peak when the optical path length difference between the first test surface 1 14a and the first reference surface 1 16a is zero and interference fringes from the second interferometer 108b that peak when the optical path length difference between the second test surface 1 14b and the second reference surface 116b Is zero. If the thickness of the reference sample 112 is known, the thickness of the test sample 1 10 may be determined based on the known thickness an the difference between the peak locations associated with the signals from the first interferometer 108a and the second interferometer 108b.

[00513 For example, the determination of the thickness of the test sample 110 (e.g , in step 208} using the first interferometer 108a in FIG. 1C may be described by the following equations. However, it is to be understood that the configuration of the first interferometer 108a illustrated in FSG. 10 as well the corresponding equations below are provided solely for illustrative purposes and should not be interpreted as limiting. Rather, similar formulations may be generated for additional configurations of an interferometer 108 {e.g., the second interferometer 108b in FIG. 1C, the interferometers 108 in FIG. 1B, or any alternative configuration).

[0052] The electric field of light reflected from the test sample 1 10 {¾) and from the reference sample 1 12 (¾} projected to the detector 136 may be described as:

where t _s$ and r _BS are the transmission and reflection coefficients of the beamsplitter 130, ¾ is the reflection coefficient of the test sample 1 10, r _R is the reflection coefficient of the reference sample 112, r _M is the reflection coefficient of the mirror 148, w is the spectral frequency of the source beam 104, c is the speed of light, % is the tee-space length of the sample arm 132a of the first interferometer 108a, z _R is the free-space length of the reference arm 134a of the first interferometer 108a, f _;ί is the phase generated by any optical components in the sample arm 132a, <p _R is the phase generated by any optical components in the reference arm 134a, and ¾(w) describes the shape of the source beam 104.

[0053] The intensity of light {/(«)) on the detector 136 may then be: where i? is the responsivity of the defector 136.

[0054] !n a non!imiting example of a Gaussian source beam 104, the intensity of Sight on the detector 136 (/(w)} may be written as: with

where A ₀ is the maximum spectra! intensity, w _< is the peak frequency, and s _w is the standard deviation of the spectrum of the of the source beam 104, respectively.

[00S§| The overall intensity on the detector 136 may then be obtained by integrating the intensity /(<¾>) over time:

and d is a constant path length related to the optica! components in the arms of the interferometer 108.

[00563 The result of this mode! is that each interferometer 108 (e.g., interferometers 108a, 108b) generates an interference signal during the scan with a shape of a raised cosine with a Gaussian envelope. Further, the peak of the Gaussian envelope for each interferometer 108 corresponds to the condition based on Equation (8), which corresponds to the position at which the path lengths of the sample arm 132a and the reference arm 134a are matched for that interferometer 108.

[0057] As a result, the thickness of the test sample 110 may be related to the distance between the peaks of the interference signals from the two interferometers 108 (e.g., the peak separation distance) and the thickness of the reference sample 112. 0055} However, it is to be understood that the equations above associated with a Gaussian beam are provided solely for illustrative purposes and should not be interpreted as limiting. Similar equations may be formulated for beams having different profiles.

[oess] FIG. 3 is a conceptual view of the sample arm 132 and reference arm 134 of each interferometer 108, in accordance with one or more embodiments of the present disclosure. St is noted that FIG 3 may apply regardless of the particular optical components in each ar of an interferometer 108. As illustrated in FIG. 3, the combined path of the sample arm 132 of the first interferometer 108a, the sample arm 132 of the second interferometer 108b, and the thickness (T _s ) of the test sample 110 is equal to the combined path of the reference arm 134 of the first interferometer 108a, the reference arm 134 of the second interferometer 108b, and the thickness (T _R ) of the reference sample 112. In this regard, ¾ - Z _s in FIG 3.

[00603 Further, FIG. 3 illustrates a position of the reference sample 112 at which the path lengths of the second interferometer 108b incorporating the second test surface 1 14b and the second reference surface 118b are equal. In particular, the path lengths of the second interferometer 108b satisfy the following condition at this location: which corresponds to a peak of the interference signal from the second interferometer 108b based on Equations (8) and (12) above.

[0061] Similarly, translating the reference sample 112 by a distance o1 &z _p (e.g., the peak separation distance) makes the path lengths of the first interferometer 108a incorporating the first test surface 114a and the first reference surface 1 1©a equal. At this position (not shown), path lengths of the first Interferometer 108a satisfy the following condition: which corresponds to a peak of the interference signal from the first interferometer 108a based on Equations (8) and (12) above.

[00621 Once determined, the peak separation distance z _p may be related to the thickness (T _s ) of the test surface 114. For example, given that ¾ - Z _s which simplifies to:

T _s άz _R + T _R . (16)

[0063| Steps for determining the pea separation distance &z _p will now be described in greater detail 0064J FIG. 28 is a flow diagram illustrating sub-steps for determining the thickness (T _s ) of the test sample 110 based on the peak separation distance &z _p and the thickness (T _R ) of the reference sample 112 (e.g., associated with step 208), in accordance with one or more embodiments of the present disclosure. 00651 it s recognized herein that while the peak of an interference signal during a scan of the linear translation stage 1 18 may theoretically occur when the sample arm 132 and the reference arm 134 of an associated interferometer 108 are matched, the sampling resolution, noise, or other fluctuations may result in a difference between a location of the linear translation stage 118 associated with a peak detected value {e.g., a sampled value) and the location where the samp!e arm 132 and the reference arm 134 are matched. Accordingly, it may be desirable to apply one or more signal processing techniques to provide an accurate and robust technique for determining the peak locations of the first and second interference signals. 0066J in one embodiment, the step 208 indudes the step 210 of determining envelopes of the first and second interference signals in another embodiment the step 208 includes the step 212 of determining locations of the linear translation stage 1 18 corresponding to peaks of the first and second interference signals (e.g., peak locations). In another embodiment, the step 208 includes the step 214 of determining the thickness (T _s ) of the test surface 1 14 based on the thickness (T _R ) of the reference sample 112 and a distance between the peak locations (&z _p ). For example. Equation (16) above may be used to determine the thickness (¾} of the test surface 114 based on the thickness (T _R ) of the reference sample 1 12 and distance between the peak locations (&z _p ).

(00673 It may be the case that determining a peak location of a relatively slow-varying envelope function of the interference fringes may be determined with a greater degree of accuracy and/or reliability than determining a peak location of the first and second interference signals directly. Further, as will be discussed in greater detail below, in the case that the interference signals are sampled, it may be the case at least one of the interference signals are not sampled at the precise location of the linear translation stage 1 18 at which the arms of the associated interferometer 108 are matched. toosaj Envelope functions associated with the first and second interference signals (e.g. , step 210) may be determined using any technique in the art. Further, the step 208 and any of the associated sub-steps above (e.g., steps 210-214) may be implemented using any combination of analog or digital processing techniques. For example, envelope functions associated with the first and second interference signals (e.g., step 210) ma be determined by applying a low-pass filter (either digital or analog) to the first and second interference signals to remove the high-frequency oscillations associated with interference.

[00693 FIG. 2C is a flow diagram illustrating sub-steps for determining enveiopes of the first and second interference signals using digital signal processing techniques, in accordance with one or more embodiments of the present disclosure. In one embodiment, the step 210 indudes the step 216 of sampling the first and second interference signals (e.g. using an analog to digital converter 128). For example, it may be the ease that the first and second interference signals generated by the detectors 136 during a scan are analog signals. Accordingly, sampling the interference signals may enable the use of digital signal processing techniques for determining the envelopes of the first and second interference signals. 00703 The first and second interference signals may be sampled using any technique known in the art. For example, the first and second interference signals may be sampled at regular location intervals based on a hardware position trigger from the linear translation stage 118, By way of another example, the first and second interference signals may be sampled at regular time intervals based on a clock signal.

[00713 In one embodiment the step 210 includes the ste 218 of reconstructing the first and second interference signals from sampled first and second interference signals and the step 220 of determining the envelopes of the first and second interference signals based on the reconstructed first and second interference signals. Reconstructed signals may be generated (e,g„ in step 218) using any technique known in the art. For example, sampled interference signals may be reconstructed using one or more interpolation techniques (e.g., polynomial interpolation, spline interpolation, or the like) such that unsampled data between the sample data points may be estimated. By way of another example, sampled interference signals may be fit to one or more functions derived from theory and/or simulations using one or more curve-fitting techniques {e.g., regression, or the like). For instance, sampled interference signals may be fit based on Equations (4)- (7) above. Further, one or more smoothing operations may be applied to the reconstructed interference signals. Similarly, any combination of interpolation, curve fitting, smoothing techniques, or the like may be applied to envelope signals generated based on reconstructed interference signals (e.g., in step 220). For example, envelope signals generated based on reconstructed interference signals may be further processed to mitigate noise or other fluctuations in the envelope to facilitate the determine of the peak location corresponding to the location of the linear translation stage 118 at which the sample arm 132 and the reference arm 134 of a given interferometer 108 are matched. [0072| FIG. 4A is a plot of a sampled interference signal 402, a reconstructed interference signal 404, an envelope of the reconstructed interference signal 408, and a simulated Gaussian envelope 408, in accordance with one or more embodiments of the present disclosure. For example, the sampled interference signal 402 of FIG. 4A has a sampling resolution of 100 nm and the reconstructed interference signal 404 is generated with a 10 n resolution.

[00731 t s recognized herein that the accuracy of an envelope generated from sampled data as opposed to theoretical (or analog) data may generally depend on the extent to which sampled points track the contours of the theoretical data. As illustrated in FIG. 4A, the sampled interference signal 402 may not include sampled points at the peaks of the interference fringes such that an envelope function based solely on the sampled Interference signal 402 may include significant errors. In contrast, the reconstructed interference signal 404 is generated with sufficient resolution to provide data at peaks of the interference fringes. Accordingly, the envelope of the reconstructed interference signal 406, corresponding to an envelope generated based on the sampled interference signal 402 closely tracks the peaks of the interference fringes. Further, the envelope of the reconstructed interference signal 406 provides excellent agreement with a simulated Gaussian envelope 408 (e.g , based Equations { 1 )-( 1 1 ) above).

[00741 PIG. 4B is a plot of sampled first and second interference signals, reconstructed first and second interference signals, envelopes of the first and second reconstructed signals, and Gaussian envelopes for the first and second interference fringes associated with the first and second interferometers 108a, 108b, in accordance with one or more embodi ments of the present disclosure,

[00753 In particular, the rightmost set of signals is generated by the second interferometer 108b and corresponds to the plot in FIG. 4A, while the leftmost set of signals is generated by the first interferometer 108a and includes a sampled interference signal 410, a reconstructed interference signal 412, an envelope of the reconstructed interference signal 414, and a simulated Gaussian envelope 418. [0076] The peak separation distance { &z _p ) may thus be determined based on a difference between the peak locations of the envelopes of the first and second reconstructed interference signals 406, 414. Further, the locations of the peaks (e.g., in step 212) as well as the peak separation distance (Az _p ) may be determined using any technique known in the art. in one embodiment, a peak location for an interference signal may be determined by identifying a location corresponding to zero phase of the interference signals (e.g., the first or second interference signals) in the vicinity of a peak. For example, the method 200 may include obtaining phases of the first and second interference signals in vicinities around the peaks and identifying the peak locations as locations where the phases of the first and second interference signals are zero.

[0077] Referring again to FIGS. 2A through 2C, the method 200 may include one or more verification steps. For example, the metho 200 may include a signal strength verification step to ensure that signal strength on at least one detector 136 is above selected threshold. In the case that the signal strength is not above the selected threshold the method 200 may further include one or more corrective steps. For instance, the method 200 may include increasing a power of the source beam 104. In another instance, the method 200 may include modifying the spectrum (e.g., operating band) of the source beam 104. In this regard, the spectrum of the source beam 104 may be tuned to include wavelengths suitable for providing increased signal strength such as, but not limited to, wavelengths at which the test sample 110 has a higher reflectivity. By way of another example, the method 200 may include verifying the shape and/or fit of an envelope of an interference signal (e.g., in step 210) for either interferometer 108. For instance, the method 200 may include that an envelope function fits a Gaussian distribution within a selected tolerance. In the case that the shape and/or fit Is not within a selected tolerance, the method 200 may include one or more corrective steps such as, but not limited to, repeating a measurement after modifying the intensity and/or spectrum of the source beam 104, or applying a different technique to determine the peak separation distance (Dz _r ).

[0078] Referring now to FIG. 5, dual interferometry thickness measurements described herein may measure thickness variations at multiple locations of a sample. FIG. 5 includes spatially-resolved dual interferometry thickness measurements of samples having step features with heights verified by atomic force microscopy, in accordance with one or more embodiments of the present disclosure. In particular, plot 502 includes a measurement of a sample with a known step size of 517 nm as 500 nm, plot 504 includes a measurement of a sample with a known step size of 4.7 pm as 4.6 pm, plot 506 includes a measurement of a sample with a known step size of 0.98 pm as 1.0 pm, and plot 508 includes a measurement of a sample with a known step size of 9.4 pm as 9.3 pm.

[0079] As described previously herein, dual interferometry thickness measurements as described herein may provide spatially-resolved thickness measurements through various techniques. By way of another example, dual interferometry with a spatially- extended beam coupled with a muSti-pixei detector may simultaneously provide thickness measurements for multiple locations on the sample within the extended area.

[00S0] Referring now to FIG. 6, dual interferometry may provide highly repeatable measurements with short measurement times. FIG. 6 is a plot illustrating 36 repeate measurements of a 300 mm sample wafer having a nominal thickness of 776 pm, in accordance with one or more embodiments of the present disclosure. As illustrated in FIG. 6, the repeated measurements exhibit an average thickness value of 776.010 p with a standard deviation of 32 nm.

[0081] The herein described subject matter sometimes illustrates different components contained within, or connected with, other components. It is to be understood that such depicted architectures are merely exemplary, and that in fact many other architectures can be implemented which achieve the same functionality. In a conceptual sense, any arrangement of components to achieve the same functionality is effectively "associated" suc that the desired functionality is achieved. Hence, any two components herein combined to achi eve a particula r functionality can be seen as’’associated with" each other such that the desired functionality is achieved, irrespective of architectures or intermedia! components. Likewise, any two components so associated can also be viewed as being “connected" or“coupled” to each other to achieve the desired functionality, and any two components capable of being so associated can also be viewed as being "couplable” to each other to achieve the desired functionality. Specific examples of coupiable include but are not limited to physically interactable and/or physically interacting components and/or wirelessly interactable and/or wirelessly interacting components and/or logically interactable and/or logically interacting components. 00823 It is believed that the present disclosure and many of its attendant advantages will be understood by the foregoing description, and if will be apparent that various changes may be made in the form, construction, and arrangement of the components without departing from the disclosed subject matter or without sacrificing ali of Its material advantages. The form describe is merely explanatory, and it is the intention of the following claims to encompass and include such changes. Furthermore, it is to be understood that the Invention is defined by the appended claims.