Atomic layer etching (ALE) is a multistep process used today in manufacturing for removing ultrathin layers of material. In this article, the authors report on ALE of Si, Ge, C, W, GaN, and SiO2 using a directional (anisotropic) plasma-enhanced approach. The authors analyze these systems by defining an “ALE synergy” parameter which quantifies the degree to which a process approaches the ideal ALE regime. This parameter is inspired by the ion-neutral synergy concept introduced in the 1979 paper by Coburn and Winters [J. Appl. Phys. 50, 5 (1979)]. ALE synergy is related to the energetics of underlying surface interactions and is understood in terms of energy criteria for the energy barriers involved in the reactions. Synergistic behavior is observed for all of the systems studied, with each exhibiting behavior unique to the reactant–material combination. By systematically studying atomic layer etching of a group of materials, the authors show that ALE synergy scales with the surface binding energy of the bulk material. This insight explains why some materials are more or less amenable to the directional ALE approach. They conclude that ALE is both simpler to understand than conventional plasma etch processing and is applicable to metals, semiconductors, and dielectrics.

Although optical lithography has been extended to far smaller dimensions than was predicted 15 years ago, there are definite physical barriers to extending it to the minimum dimensions of 70 nm that are projected to be required 15 years from now. Both focused, point electron beams and ion beams have been used to write dimensions in resist well below 20 nm, albeit at speeds far too slow for production lithography. Projection systems, which employ a mask and, in effect, produce a large array of beams, can provide both small minimum dimensions and high throughput. Ions are particularly well suited for this because they suffer little or no scattering in the resist, the linewidth is not a strong function of dose (good process latitude), and the resist sensitivity is relatively independent to resist thickness or ion energy. IMS in Vienna, Austria has built two generations of ion projection lithography systems which have demonstrated many of the features needed for high throughput lithography. In these systems a stencil mask is irradiated with a uniform beam of light ions, H+, H2+, or He+, and the transmitted pattern is demagnified (by 10× to 3×) and focused on a resist covered wafer at energies in the 70–150 keV range. So far, minimum dimensions down to 70 nm line-space pairs have been demonstrated, drift has been eliminated with a “pattern lock” servo system, and field distortion of less than 0.15 μm over 8×8 mm has been measured in agreement with calculations. Based on these achievements a new generation ion lithography machine has been designed which uses 3× demagnification and will expose a 20×20 mm field at 0.12 μm minimum dimensions with less than 10 nm of distortion introduced by the ion optics. Global and stochastic space charge effects have been modeled and, in some cases, measured with the existing machines. Stochastic space charge effects will not cause unacceptable blur in the new design if the total ion current is kept below 3 μA. At this total current the time to expose one chip is still of order 0.5 s so that the calculated throughput is about 70 wafers (200 mm) per hour. Ion sources with low energy spread (∼2 eV) have been developed and will provide uniform illumination of the mask. Stencil mask fabrication on membranes of 2.5-μm-thick silicon has been developed. Distortion of the pattern cut in the membrane due to stress relief has been modeled, and with proper mask design can be kept below 20 nm (6.7 nm on the wafer). According to calculations and measurements mask distortion due to ion beam heating can be reduced to a negligible level if a radiation cooling cylinder is used. As a result of the building and evaluation of the existing machines and the design of the next generation, significant progress has been made in ion projection lithography which we will review in this article. The next step in the development of ion projection lithography is being conducted by the MEDEA program in Europe, which will develop a full field processing tool.

High resolution patterns have been fabricated in 〈100〉 silicon by doping selected areas with gallium utilizing an ion microprobe. These doped regions are used as an etch mask for subsequent anisotropic etching of silicon. The etching was performed in a KOH:IPA solution at 80–90 °C. The resulting etch rate of the doped silicon is approximately inversely proportional to the gallium impurity concentration. At high doping concentrations an etch rate difference of greater than 1000:1 has been measured between the virgin silicon and the doped regions. Using this technique features as small as 30 nm have been produced.

Plasma assisted atomic layer etching (ALE) has recently been introduced into manufacturing of 10 nm logic devices. This implementation of ALE is called directional ALE because ions transfer momentum to the etching surface during the removal step. Plasma assisted directional ALE can be described as sputtering of a thin modified layer on the surface of the unmodified material. In this paper, the authors introduce a collision cascade based Monte Carlo model based on sputtering theory which has evolved for over 50 years [P. Sigmund, Thin Solid Films 520, 6031 (2012)]. To test the validity of this approach, calculated near threshold argon ion sputtering yields of silicon and chlorinated silicon are compared to published experimental data. The calculated ALE curve for Cl2/Ar ALE of tantalum is in good agreement with the experiment. The model was used to predict the presence of salient sputtering effects such as ion mass and impact angle dependence, as well as redeposition in directional ALE. Finally, the authors investigate time dependence of the synergy parameter for ion energies above the sputtering threshold of tantalum for Cl2/Ar ALE. The calculations show that close to 100% synergy can be obtained for short periods of time which opens a path to accelerate directional ALE. Very precise control of all process parameters as a function of time is prerequisite to realize this process space.

Daily feed use, water use, body weight, and mortality of Cobb x Cobb male broilers over 8-wk growout periods were measured for 10 consecutive growouts in four commercial-scale broiler houses (121.0 x 12.1 m each). Polynomial equations were developed to relate bird age to body weight, daily feed and water use, cumulative weekly feed and water use, and cumulative mortality. Weekly feed conversion was derived from growth and feed use data and was depicted by a third-order polynomial equation. Dead bird weight was calculated using mortality and body weight of the broilers and related to bird age with three polynomial equations over the growth period. Total dead bird weight averaged 76 kg per 1,000 birds placed, of which 10 kg or 13% occurred during the first 5 wk and the remaining 66 kg or 87% occurred during the last 3 wk of the growout periods. Results of this study provide a realistic data base for mathematical modeling of production responses and a guideline for management planning in commercial male broiler operation.