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Abstract
Purpose – Process variation has become a major concern in the design of many nanometer circuits, including interconnect pipelines. The purpose of
this paper is to provide a comprehensive overview of types and sources of all aspects of interconnect process variations.
Design/methodology/approach – The impacts of these interconnect process variations on circuit delay and cross-talk noises along with the two
major sources of delays – parametric delay variations and global interconnect delays – have been discussed.
Findings – Parametric delay evaluation under process variation method avoids multiple parasitic extractions and multiple delay evaluations as is done
in the traditional response surface method. This results in significant speedup. Furthermore, both systematic and random process variations have been
contemplated. The systematic variations need to be experimentally modeled and calibrated while the random variations are inherent fluctuations in
process parameters due to any reason in manufacturing and hence are non-deterministic.
Originality/value – This paper usefully reviews process variation effects on very large-scale integration (VLSI) interconnect.
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Effects of process variation in VLSI interconnects Microelectronics International
K.G. Verma, B.K. Kaushik and R. Singh Volume 26 · Number 3 · 2009 · 49 –55
impact analysis on micro architecture (Borkar et al., 2003) Errors in deep-submicron (DSM):
and delay fault (Gattiker et al., 2001) test under process The number of transient errors is expected to increase in
variation (Luong and Walker 1996; Liou et al., 2002; Krstic future technology generations:
et al., 2003; Lu et al., 2004a). Since the width, thickness and .
Interconnects will be longer.
spacing of interconnects are each scaled by 1/a .
Smaller feature size brings new error sources (like
(scaling factor), cross-section areas must scale by 1/a2. The radiation).
length of short distance interconnections is scaled by 1/a, so .
The physical implementation of circuits and interconnects
that resistance is increased by a. With decreasing device is expected to function erroneously from time to time.
dimensions, we see increase in the levels of integration and .
Designs cannot be considered nearly 100 per cent reliable
consequent increase in die size. This lengthens the anymore.
interconnections from one side of the chip to the other end
Sources of DSM errors:
and, therefore, both resistance and capacitance of .
cross-talk;
interconnects are increased, producing much larger time .
electro-magnetic interference;
constants. Thus, the effects of increased propagation delays, .
radiation;
signal decay, and clock skew will reduce the maximum .
process variations; and
achievable operating frequency, even though the smaller .
other.
transistors produce gates with less delay. One solution to this
problem has been to make use of multilayer interconnections Given the perspective of different categories of variation, we
with thicker, wider conductors and thicker separating layers. can now briefly survey some of the specific process variations
Other method is to use cascaded drivers and repeaters to typically of concern in evaluating devices and interconnect in
reduce the effects of long interconnect. A further option is to integrated circuit design.
use optical interconnection techniques where a very high level
of interconnection methodology is required (Fabbro et al., 2.1 Device geometry variations
1995). The first set of process variations of concern relate to the
Figure 1 shows a typical interconnect geometry in a custom physical geometric structure of MOSFET and other devices
design layout (Liu et al., 2000). Interconnects on adjacent (resistors and capacitors) in the circuit. These typically
layers are orthogonal to each other, which is a special case of include.
the general configuration. The top interconnect has larger Film thickness variations. The gate oxide thickness is a
width and smaller length compared to lower interconnects. critical but usually relatively well controlled parameter.
The capacitance at any metal line or node consists of the Variation tends to occur primarily from one wafer to
following three components: another with good across wafer and across die control.
1 overlap capacitance Cov due to the overlap between two Other intermediate process thickness variations (e.g. poly or
interconnects in different metal layers; spacer thickness) can impact channel length, but are rarely
2 lateral capacitance C lat between two intra-layer directly modeled.
interconnects; and Lateral dimension variations. Lateral dimensions (length and
3 fringe capacitance Cfr between two interconnects in width) typically arise due to photolithography proximity
different metal layers; this fringe capacitance is between effects (a systematic pattern dependency), mask, lens, or
the sidewall of one interconnect and the top (or bottom) photo system deviations (a repeated die dependent variation,
of another interconnects in a different layer (Pucknell and though not directly a function of the layout density or other
Eshraghian, 1988). layout parameters); or plasma etch dependencies (which can
have both wafer scale etch rate dependencies, as well as layout
2. Nanometer process variation density, aspect ratio, or other dependencies). MOSFETS are
well known to be particularly sensitive to effective channel
As the technology reaches deep submicron or nanometer
length (and thus to poly gate length and spacer width), as well
regime, the errors due process variations becomes prominent.
as gate oxide thickness and to some degree the channel width.
The errors are briefly enumerated as follows.
Of these, channel length variation often is singled out for
particular attention. This is due to the fact that such
Figure 1 Schematic of a typical interconnect structure variations have direct impact on device output current
characteristics (Yu et al., 1996).
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Effects of process variation in VLSI interconnects Microelectronics International
K.G. Verma, B.K. Kaushik and R. Singh Volume 26 · Number 3 · 2009 · 49 –55
51
Effects of process variation in VLSI interconnects Microelectronics International
K.G. Verma, B.K. Kaushik and R. Singh Volume 26 · Number 3 · 2009 · 49 –55
M3 height M3 width
60 40
s/m = 3.0 s/m = 4.6
50 ×100 ×100
30
40
30 20
20
10
10
0 0
0.02 1.12 1.32 1.52 (mm) 0.75 0.91 1.07 1.22 (mm)
Source: Boning and Nassif (2000)
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Effects of process variation in VLSI interconnects Microelectronics International
K.G. Verma, B.K. Kaushik and R. Singh Volume 26 · Number 3 · 2009 · 49 –55
simultaneously. It is well known that an adjacent switching Surface and grain boundary scattering of electrons increases
aggressor can either slow down or speed up a victim the resistance for narrow width wires. As technology
depending on its switching polarity with respect to the continues to scale, the tail would become more prominent
victim. The victim becomes slower in the case of out-of-phase due to increased electron scattering effect. The delay
switching and faster due to in-phase switching. The delay distribution using Monte Carlo simulations shows that, even
push-out during out-of-phase switching is a major concern with large variations in geometric dimensions, the delay
due to the possibility of setup-time failures, and hence, must distribution remains Gaussian.
be accounted for in order to ensure correct operation of the Characterizing and managing process variations of
circuit. The dynamic-delay modeling with and without interconnect geometry is becoming critical for 0.13 m and
process variations can ascertain the effect of process below. Delay analysis can no longer ignore process variations
variations. for 0.13 m and below technologies. Individual parameter
Cross-talk noise is relatively less Gaussian than cross-talk sensitivity analysis show that the delays are most influenced by
delay. The propagated noise is even less Gaussian. This can the interconnect resistance and capacitance (Lu et al., 2004b).
be attributed to non-linear nature of the transfer functions of
the CMOS gates. 4.3 Parametric delay evaluation under process variation
In order to address the effect of process variation, the various
4.2 Delays due to interconnect variation methods are:
Interconnects have turned out to be most crucial factor of .
clock skew analysis under process variation;
signal delays, especially, in deep and very deep submicron .
statistical performance analysis;
designs. Timing margin have become so small as frequencies .
worst case performance analysis parametric yield
increase that even pico-second variations can no longer estimation;
be ignored, in particular for high-speed clock design. Global
.
impact analysis on micro architecture; and
interconnect delay increases as technology scales down. To
. delay fault test under process variation.
mitigate the global interconnect delay problem metal wires In all the above research, one important task is to compute
have been scaled in a selective fashion. Optimal buffer variational path delay under process variation, either as
insertion methods, which reduce delay from quadratic to functions of process variables or as random variables of
linear, become difficult as the number of buffers increase at a certain distribution. However, the conventional methods to
fast rate. The proliferation of buffers also leads to increased compute path delay are either slow or inaccurate. The
power in designs. Alternatives to buffer insertion have been response surface method (RSM) performs multiple
proposed, some of which include static source-follower driver simulations to obtain high accuracy; the RSM method must
(Kil et al., 2006), differential current sensing, and multilevel perform multiple parasitic extractions under different process
signaling. In multilevel signaling approach, matching conditions (Brawhear et al., 1994; Acar et al., 2001; Gattiker
and proper sizing of the driver and receiver transistors is et al., 2001; Fabbro et al., 1995). Since, there are a large,
done and it is thus prone to process variations, resulting in number of metal layers in the modern technology, there are
doubled bandwidth and delay comparable to buffer insertion. many interconnect process variables. For example, for a
Simply scaling down the supply voltage, undesirable k-layer technology, there are 3 k process variables,
characteristics of scaled CMOS, such as drain induced corresponding to the metal width, metal thickness and
barrier lowering, quantum mechanical gate tunneling, and inter-layer dialectic thickness of each layer. Thus, the
punch through can also be alleviated. In the sub-threshold traditional RSM becomes prohibitive for large circuits.
region, the MOS gate capacitance is significantly less than Another method Parametric Delay Evaluation (PARADE)
that in the super-threshold region due to the channel for fast using analytical formulae and pre-characterized
depletion capacitance that appears in series with the oxide lookup tables is used to estimate for the interconnect delays.
capacitance Kil et al. (2006). Unlike MOS gate capacitance, In this method variational path delays is evaluated efficiently,
the wire capacitance value is independent of the supply based on the lumped C delay model and based on the effective
voltage. As a result, the CV/I delay of wires increase more capacitance delay model, respectively. No multiple parasitic
steeply than that of logic gates in subthreshold circuits, extractions and multiple delay evaluations are needed
exacerbating the global interconnect delay problem. (Lu et al., 2004b). The efficiency of this method makes it
To first order, delay through an interconnect can be possible to comprehensively analyze circuit performance on all
expressed as the RC product of its resistance and capacitance. interconnect and device process variables for large circuits.
With any change in the physical dimensions of the wire, its Compared to the traditional RSM, the delay error is within
resistance and capacitance also change, causing interconnect 7 per cent using analytical methods, and is within 1 per cent
delay to fluctuate. In order to model the impact of variability using the table lookup method in PARADE (Lu et al., 2004b.
on wire delay, one needs to capture the effect of geometric Thus, PARADE method avoids multiple parasitic extractions
variations on the electrical parameters. The change in and multiple delay evaluations as did in the traditional RSM,
electrical parameters due to variations in geometric and results in significant speedup. Since this method is based
dimensions can be captured by the simple linear on effective capacitance delay model it achieves higher
approximation. accuracy (Lu et al., 2004b).
The thickness of metal lines can vary at the bottom due to
etch effects. CMP effect influences the thickness variation
5. Interconnect analysis
from the top of the metal, varying the interwire resistance and
capacitance. Though the distribution of resistance is fairly By accounting for systematic part of process variation in
Gaussian, the tail of the distribution can be attributed to non- timing analysis, uncertainty in interconnects analysis can be
linear increase in resistance due to electron scattering effects. reduced, thereby achieving closer bound for circuit
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Effects of process variation in VLSI interconnects Microelectronics International
K.G. Verma, B.K. Kaushik and R. Singh Volume 26 · Number 3 · 2009 · 49 –55
performance. One way of random analysis is to use OPERA reduction in the parametric yield. Thus, determining an
technique that models the stochastic response in an infinite accurate statistical description (e.g. moments, distribution,
dimensional Hilbert space in terms of orthogonal polynomials etc.) of the interconnect’s response is critical for designers. In
expansions (Vrudhula et al., 2006). It is the prototype the presence of significant variations, device or interconnect
software that has the capability to carry out a SPICE Monte model parameters such as wire resistance, capacitance, etc.
Carlo analysis. Using such a polynomial representation, need to be modeled as random variables or as spatial random
there is no need to repeatedly generate samples of the random processes. Furthermore, in addition to metal thickness and
parameters, and solve the system as required in Monte Carlo width variation, damaged dielectric regions on the side of the
approach. The accuracy in obtaining the variance by OPERA metal lines are important contributions to cross-talk and
can be increased further by increasing the order of the delays. It has also been comprehended that process variations
expansion. This provides an attractive alternative to the are not completely random data. The systematic part of
computationally expensive Monte Carlo simulations (Wang variations plays an important role in deviating electrical
et al., 2004). parameters.
Typically, ITP are fixed by parasitic extractors and a single
fixed value is used for the ILD or metal thickness of each
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Corresponding author
Malavasi, E., Zanella, S., Min, C., Uschersohn, J., Misheloff, M.
and Guardiani, C. (2002), “Impact analysis of process B.K. Kaushik can be contacted at: brajesh_k_k@yahoo.com
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