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Artificial intelligence (AI) is increasingly used to solve multi‐objective problems and reduce the turnaround times of semiconductor processes. However, only brief AI explanations are available for process/device/circuit engineers to provide holistic feedback on the manufactured results. Herein, linear/nonlinear variation decomposition (LVD/NLVD) of neural networks is demonstrated to quantitatively evaluate the influence of unit processes on the figure of merit (FoM) and co‐analyze the unit process influences with device characteristic behaviors. The NLVD can evaluate the output variation from each input of neural networks in an individual sample, although neural networks are not available in an analytic form. The NLVD is successfully verified by confirming that a) the output and summation of all decomposed output variations perfectly coincide and b) the process influences on the FoM are decomposed to 6.01–54.86% more accurately compared with those of LVD in 1Y nm node dynamic random‐access memory test vehicles with a baseline and split tests introducing high‐k metal gates with a minimum gate length of 1 A nm node for further node scaling. The approaches identify defective processes and defect mechanisms in each sample and wafer, which enhance causal analyses for individual cases in diverse fields based on regression artificial neural networks.

Grain boundary (GB) at the source/drain (S/D) epitaxy was investigated using fully-calibrated TCAD. Because the S/D epi is grown separately at the bottom and the NS channels, nanosheet field-effect transistors (NSFETs) have unwanted GB within the S/D epi which fully relaxes the channel stresses. This GB changes the doping profiles and the stress values, which thus degrade the DC performances. We focused on single GB with different inclined angles and positions. N-type NSFETs have similar DC performances regardless of the GB since the changes of doping and stress were small. P-type NSFETs suffer from DC performance degradations but different depending on the GB positions. As the GB splits the p-type S/D epi into two, lower S/D below the GB has tensile stress and upper S/D above the GB has compressive stress. Since tensile stress increases boron diffusivity, more boron dopants diffuse into the NS channels as the device has lower S/D region, thus suffering the short channel effects greatly. The device having upper S/D region loses the channel stress much, so it degrades the on-state performance. This study provides clear understanding of the GB effects of NSFETs.

For the first time, we suggested that the monolithic 3D (M3D) static random access memory (SRAM) with gate and S/D bottom contact (GBC and SDBC) schemes (SRAMSDGBC) and analyzed they could significantly improve the power, performance, and area (PPA) compared to the conventional M3D SRAM (SRAM3D). SRAM3D could not directly connect the top-tier device and the bottom-tier metal line. Thus two tiers had to be connected by bypassing the metal line. As a result, SRAM3D wasted the area to place the monolithic interlayer via and did not get 50 % area scaling. However, gate and S/D bottom contact schemes, GBC and SDBC, could solve these problems. Although these methods required additional process steps, they brought significant advantages in interconnect RC and PPA. Based on a 26 nm width nanosheet transistor, SRAM3D showed a 30 % area reduction compared to 2D SRAM (SRAM2D), whereas SRAMSDGBC showed a 50 % area reduction. In the ideal (worst) case which ignoring (considering) the array resistance, the read and write access time of SRAMSDGBC were improved 7.7 % (19 %) and 8.3 % (33 %) than SRAM3D, and the write dynamic power was improved by 5.9 % (5 %). Especially, SRAMSDGBC showed improved PPA in the worst case compared to SRAM2D_Cu, which had relatively small interconnect resistivity. Namely, GBC and SDBC schemes are essential to enhance the PPA of M3D cells and will be a promising scheme in M3D SRAM and other logic cells.

This study proposed a novel source/drain (S/D) extension scheme to increase the stress in nanosheet (NS) field-effect transistors (NSFETs) and investigated the scheme by using technology-computer-aided-design simulations. In three-dimensional integrated circuits, transistors in the bottom tier were exposed to subsequent processes; therefore, selective annealing, such as laser-spike annealing (LSA), should be applied. However, the application of the LSA process to NSFETs significantly decreased the on-state current (Ion) owing to diffusionless S/D dopants. Furthermore, the barrier height below the inner spacer was not lowered even under on-state bias conditions because ultra-shallow junctions between the NS and S/D were formed far from the gate metal. However, the proposed S/D extension scheme overcame these Ion reduction issues by adding an NS-channel-etching process before S/D formation. A larger S/D volume induced a larger stress in the NS channels; thus, the stress was boosted by over 25%. Additionally, an increase in carrier concentrations in the NS channels improved Ion. Therefore, Ion increased by approximately 21.7% (37.4%) in NFETs (PFETs) compared with NSFETs without the proposed scheme. Additionally, the RC delay was improved by 2.03% (9.27%) in NFETs (PFETs) compared with NSFETs using rapid thermal annealing. Therefore, the S/D extension scheme overcame the Ion reduction issues encountered in LSA and significantly enhanced the AC/DC performance.

The inner spacer thickness (TIS) variations in sub-3-nm, node 3-stacked, nanosheet field-effect transistors (NSFETs) were investigated using computer-aided design simulation technology. Inner spacer formation requires a high selectivity of SiGe to Si, which causes inevitable TIS variation (ΔTIS). The gate length (LG) depends on the TIS. Thus, the DC/AC performance is significantly affected by ΔTIS. Because the effects of ΔTIS on the performance depend on which inner spacer is varied, the sensitivities of the performance to the top, middle, and bottom (T, M, and B, respectively) ΔTIS should be studied separately. In addition, the source/drain (S/D) recess process variation that forms the parasitic bottom transistor (trpbt) should be considered with ΔTIS because the gate controllability over trpbt is significantly dependent on ΔTIS,B. If the S/D recess depth (TSD) variation cannot be completely eliminated, reducing ΔTIS,B is crucial for suppressing the effects of trpbt. It is noteworthy that reducing ΔTIS,B is the most important factor when the TSD variation occurs, whereas reducing ΔTIS,T and ΔTIS,M is crucial in the absence of TSD variation to minimize the DC performance variation. As the TIS increases, the gate capacitance (Cgg) decreases owing to the reduction in both parasitic and intrinsic capacitance, but the sensitivity of Cgg to each ΔTIS is almost the same. Therefore, the difference in performance sensitivity related to AC response is also strongly affected by the DC characteristics. In particular, since TSD of 5 nm increases the off-state current (Ioff) sensitivity to ΔTIS,B by a factor of 22.5 in NFETs, the ΔTIS,B below 1 nm is essential for further scaling and yield enhancement.

A novel and feasible process scheme to downsize the source/drain (S/D) epitaxy of 5-nm node bulk fin-shaped field-effect transistors (FinFETs) were introduced by using fully-calibrated TCAD for the first time. The S/D epitaxy formed by selective epitaxial growth was diamond-shaped and occupied a large proportion of the device size irrespective of the active channel area. However, this problem was solved by patterning the low-k regions prior to S/D formation by preventing the lateral overgrowth of S/D epitaxy; the so-called S/D patterning (SDP). Its smaller S/D epitaxy decreased the average longitudinal channel stresses and drive currents for NFETs. However, the small diffusions of the boron dopants into the channel regions improved the short-channel effects and alleviated the drive current reduction for PFETs. Gate capacitances decreased greatly by reducing outer-fringing capacitances between the metal-gate stack and S/D regions. Through SPICE simulation based on the virtual source model, operation frequencies and dynamic powers of 15-stage ring oscillators were studied. SDP FinFETs have better circuit performances than the conventional and bottom oxide bulk FinFETs along with smaller active areas, promising for further area scaling through simple and reliable S/D process.

In this study, threshold voltage (Vth) variability was investigated in silicon nanowire field-effect transistors (SNWFETs) with short gate-lengths of 15–22 nm and various channel diameters (DNW) of 7, 9, and 12 nm. Linear slope and nonzero y-intercept were observed in a Pelgrom plot of the standard deviation of Vth (σVth), which originated from random and process variations. Interestingly, the slope and y-intercept differed for each DNW, and σVth was the smallest at a median DNW of 9 nm. To analyze the observed DNW tendency of σVth, a novel modeling approach based on the error propagation law was proposed. The contribution of gate-metal work function, channel dopant concentration (Nch), and DNW variations (WFV, ∆Nch, and ∆DNW) to σVth were evaluated by directly fitting the developed model to measured σVth. As a result, WFV induced by metal gate granularity increased as channel area increases, and the slope of WFV in Pelgrom plot is similar to that of σVth. As DNW decreased, SNWFETs became robust to ∆Nch but vulnerable to ∆DNW. Consequently, the contribution of ∆DNW, WFV, and ∆Nch is dominant at DNW of 7 nm, 9 nm, and 12, respectively. The proposed model enables the quantifying of the contribution of various variation sources of Vth variation, and it is applicable to all SNWFETs with various LG and DNW.