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Run-to-run control of PECVD systems: Application to a multiscale three-dimensional CFD model of silicon thin film deposition

DOI:10.1002/aic.16400 期刊:AIChE Journal 出版年份:2018 更新时间:2025-09-23 15:21:21
摘要: Deposition of amorphous silicon thin films via plasma-enhanced chemical vapor deposition (PECVD) and batch-to-batch operation under run-to-run control of the associated chambered reactor are presented in this work using a recently developed multiscale, three-dimensional in space, computational fluid dynamics model. Macroscopic reactor scale behaviors are linked to the microscopic growth of amorphous silicon thin films using a dynamic boundary which is updated at each time step of the transient in-batch simulations. This novel workflow is distributed across 64 parallel computation nodes in order to reduce the significant computational demands of batch-to-batch operation and to allow for the application and evaluation in both radial and azimuthal directions across the wafer of a benchmark, run-to-run based control strategy. Using 10 successive batch deposition cycles, the exponentially weighted moving average algorithm, an industrial standard, is demonstrated to drive all wafer regions to within 1% of the desired thickness set-point in both radial and azimuthal directions across the wafer surface. This is the first demonstration of run-to-run control in reducing azimuthal film nonuniformity. Additionally, thin film uniformity is shown to be improved for poorly optimized PECVD geometries by manipulating the substrate temperature alone, without the need for re-tooling of the equipment.
作者: Marquis Crose,Weiqi Zhang,Anh Tran,Panagiotis D. Christofides
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To increase the uniformity of thin film semiconductor devices and quality of solar cell products while maintaining high production quality through the application of a run-to-run control algorithm to a multiscale, three-dimensional computational fluid dynamics model of plasma-enhanced chemical vapor deposition.

The run-to-run control algorithm, using substrate temperature correction via an exponentially weighted moving average formulation, successfully drives the amorphous silicon thin film product to within 1% of the desired thickness set-point in both radial and azimuthal directions across the wafer surface within five to six batches of operation. This approach is effective for both optimized and poorly optimized PECVD geometries, offering a novel means of deposition control without the need for re-tooling.

The computational demands of the 3D multiscale CFD model are significant, requiring days to weeks of continuous processing per batch. The model's accuracy and speed are also affected by the need to interpolate between known data points when updating boundary conditions and the inability to further decompose the microscopic kinetic Monte Carlo simulations.

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