In situmeasurements of HCl during plasma etching of poly-silicon using a diode laser absorption sensor

Tunable diode laser absorption spectroscopy is used to monitor hydrogen chloride (HCl) concentration in a commercial, high-density, low-pressure plasma reactor during plasma etching. A near-infrared diode laser is used to scan the P(4) transition in the first overtone of HCl near 1.79 m to measure changes in HCl levels. A variety of HBr and Cl 2 feedstock recipes are investigated at a process pressure of 10 mTorr as a function of rf power transformer coupled plasma, bias power and the total flow rate. Using 50 ms averaging and a signal modulation technique, we estimate a minimum detectivity of 4 10 -6 in peak absorbance, which corresponds to an HCl number density of 2 10 11 cm -3 . The diode-laser based HCl sensor is sufficiently sensitive to detect small concentration variations and HCl concentration correlates with poly-Si etch rate for the conditions studied. These measurements demonstrate the feasibility of a real-time diode laser-based sensor for etch rate monitoring and the potential for process control.