Abstract:
Methods and devices are disclosed for aligning a beam-propagation axis with the center of an aperture, especially an aperture configured to limit the aperture angle of the charged particle beam. In an exemplary method, an alignment-measurement aperture is provided at an imaging plane of a charged-particle-beam (CPB) optical system, and a beam detector is downstream of the alignment-measurement aperture. A scanning deflector is energized to cause the beam to be scanned in two dimensions, transverse to an optical axis, over the aperture. Meanwhile, the beam detector obtains an image of beam intensity in the two dimensions. In the image a maximum-intensity point is identified, corresponding to the propagation axis. Based on the two-dimensional image, the beam is deflected as required to align the propagation axis with the aperture center.

Description:
FIELD OF THE INVENTION 
     This invention pertains to,  inter alia , charged-particle-beam (CPB) optical systems as used in CPB microlithography. (Microlithography is projection-transfer of a pattern, defined by a reticle or mask, onto a sensitive substrate using an energy beam. Microlithography is a key technique used in the manufacture of microelectronic devices such as semiconductor integrated circuits, displays, and the like.) CPB optical systems typically include various CPB lenses, deflectors, and apertures. More specifically, the invention pertains to devices and methods for aligning an aperture-angle-limiting aperture with an optical axis of the CPB optical system. 
     BACKGROUND OF THE INVENTION 
     Charged-particle-beam (CPB) microlithography is a candidate new-generation microlithography technique offering prospects of better image resolution than currently obtainable with optical microlithography. A CPB microlithography apparatus includes a CPB optical system and a CPB source. The CPB source produces a suitable charged particle beam, such as an electron beam or ion beam, for use as a microlithographic energy beam. The CPB optical system typically includes CPB lenses, deflectors, and apertures. One type of aperture limits the angle at which charged particles are incident on the reticle or substrate, and hence is termed herein an “aperture-angle-limiting aperture.” 
     A conventional CPB optical system as used in a conventional CPB microlithography system is shown in FIG.  3 . The FIG. 3 system is shown and described in the context of forming and using an electron beam as a representative charged particle beam, and in the context of employing a reticle defining a pattern that is projected onto a sensitive substrate. 
     The FIG. 3 system includes a source  1 , an illumination-optical system IOS, and a projection-optical system POS. The source  1  produces an electron beam  3  that propagates in a downstream direction. The illumination-optical system IOS comprises components situated downstream of the source  1  and upstream of a reticle  9 . The projection-optical system POS comprises components situated downstream of the reticle  9  and upstream of a sensitive substrate (or “wafer”)  12 . By “sensitive” is meant that the upstream-facing surface  12   s  of the substrate  12  is coated with a suitable material (termed a “resist”) that responds in an image-imprinting way to exposure by the charged particle beam. Exposure of the resist with an image of a region (e.g., a “subfield”) of the reticle  9  causes “transfer” of an image of the respective pattern portion to the upstream-facing surface  12   s . Extending through the illumination-optical system IOS and projection-optical system POS is an optical axis A. 
     The electron beam  3  emitted from a cathode of the source  1  forms a beam crossover  2  on the optical axis A. The beam  3  propagating downstream of the beam crossover  2  is an “illumination beam” that passes through a first illumination lens  4 . The first illumination lens  4  forms an image of the cathode on a beam-shaping aperture  5  (defining typically a rectangular opening  5   a ). The beam-shaping aperture  5  trims the transverse profile of the illumination beam, according to the profile of the opening  5   a , as appropriate for illuminating the desired shape and size of individual subfields or other exposure units on the reticle. Meanwhile, the first illumination lens  4  forms an image of the beam crossover  2  on an aperture-angle-limiting aperture  7 . A maximal aperture angle of the beam  3  (as incident on the upstream-facing surface  12   s  located in the imaging plane) is imposed on the beam by the aperture-angle-limiting aperture  7 . 
     After establishing the desired transverse dimensions of individual exposed subfields and the desired range of the aperture angle, as described above, an image of the cathode is formed on the reticle  9  by a second illumination lens  8 . Portions of the illumination beam passing through a selected subfield on the reticle  9  constitute a “patterned beam” that forms an image of the illuminated subfield on the upstream-facing surface  12   s  of the substrate (“wafer”)  12 . Actual imaging is performed by a first projection lens  10  and a second projection lens  11  of the projection-optical system POS. 
     The reticle  9  defines the pattern to be exposed. In one type of conventional reticle  9  (termed a “stencil” reticle), openings are defined in a thin film or membrane (made of a silicon membrane or the like). The openings versus surrounding regions in the thin film define the pattern elements (i.e., the openings are transmissive to charged particles of the illumination beam and the membrane tends to block incident charged particles). In another type of conventional reticle  9 , termed a “scattering-membrane” reticle, pattern elements are defined by corresponding regions of a heavy-metal layer (that exhibits a high level of scattering of incident charged particles) situated on a CPB-transmissive membrane. 
     With a stencil reticle, as noted above, incident charged particles of the illumination beam not passing through an opening tend to be blocked (and absorbed) by the membrane portion of the reticle  9 . This absorption causes membrane heating, especially if the membrane is thick, which results in reticle instability. Consequently, the reticle membrane usually is made sufficiently thin to transmit (with scattering) at least some of the incident charged particles. Since incident charged particles are scattered widely by such a membrane (but not by the openings in the membrane), an aperture normally is situated downstream of the reticle  9  to absorb the scattered electrons and thus prevent them from propagating to the substrate. By absorbing these scattered charged particles, appropriate contrast is obtained of the image as formed on the substrate  12 . 
     In a conventional CPB microlithography apparatus, the center of the aperture-angle-limiting aperture  7  is located on the optical axis A. It is desirable that the propagation axis of the illumination beam be aligned with the optical axis A at the aperture-angle-limiting aperture  7 . Significant misalignment causes the distribution of beam angle on the substrate to be asymmetric, which causes substantial aberration of an image as projected onto the upstream-facing surface  12   s.    
     To avoid or minimize Coulomb effects, a recent innovation is to configure the aperture-angle-limiting aperture  7  as an annular aperture, which produces a “hollow” illumination beam. In this regard, reference is made to Japan  Kôkai  Patent Document Nos. 11-297610, filed Apr. 8, 1998, 2000-012454, filed Jun. 25, 1998, and 2000-100691, filed Sep. 21, 1998. With an annular aperture-angle-limiting aperture, misalignment of the propagation axis of the illumination beam, the optical axis A, and the center of the aperture-angle-limiting aperture  7  with each other causes marked asymmetry in the transverse distribution of beam current. Such asymmetry of beam-current density causes, in turn, a corresponding asymmetry of the Coulomb effect, making controlled reductions of the Coulomb effect especially difficult. These problems cause substantial problems with aberrations. 
     In FIG. 3, a deflector  6  normally is used to align the propagation axis of the illumination beam with the center of the aperture-angle-limiting aperture  7 . To such end, the deflection center of the deflector  6  normally is set to the position of the beam-shaping aperture  5  to prevent the image of the beam-shaping aperture  5  from shifting laterally as the deflector  6  is energized. By energizing the deflector  6 , the illumination beam is shifted laterally relative to the aperture-angle-limiting aperture  7 . While energizing the deflector  6 , the beam current incident to the aperture-angle-limiting aperture  7  is read using an ammeter  17 . The propagation axis of the illumination beam is regarded as aligned with the center of the aperture-angle-limiting aperture  7  whenever the measured current is at a minimum, indicating completion of alignment. 
     Unfortunately, in the alignment method summarized above, the current reading obtained by the ammeter  17  is extremely small in any event. Consequently, the current reading at “alignment” can be at a level that is barely detectable. Furthermore, the ammeter  17  tends to exhibit very low sensitivity at any of various locations around the actual “aligned” position. I.e., the ammeter  17  reads an integrated current from all locations on the aperture-angle-limiting aperture  7  at which the beam is incident, making it extremely difficult to ascertain any difference in a reading at an actual “aligned” position versus a position characterized by substantial misalignment. As a result, it is extremely difficult to accurately determine whether the propagation axis of the beam has been aligned properly. I.e., even though it is possible to align the propagation axis of the illumination beam with the center of the aperture-angle-limiting aperture  7 , it actually is extremely difficult to do so using the conventional approaches summarized above. 
     SUMMARY OF THE INVENTION 
     In view of the shortcomings of conventional methods and apparatus as summarized above, one object of the invention is to provide charged-particle-beam (CPB) optical systems, and CPB microlithography apparatus (including CPB point-beam writing apparatus and CPB projection-microlithography apparatus) comprising such optical systems, wherein the systems and apparatus exhibit reduced aberrations compared to conventional apparatus. Another object is to provide methods for accurately aligning the propagation axis of a CPB illumination beam with the center of an aperture-angle-limiting aperture. 
     To such ends, and according to a first aspect of the invention, methods are provided, in the context of, for example, a CPB microlithography method, for aligning the propagation axis of an imaging beam with a center of an aperture-angle-limiting aperture. In the subject CPB microlithography method, a charged-particle illumination beam, propagating from a beam source and having a respective propagation axis, is passed through an illumination-optical system that includes a lens, a deflector, and an aperture-angle-limiting aperture. In the alignment method, the following are provided: (1) a projection-optical system that forms an image of the aperture-angle-limiting aperture at an imaging plane, (2) an alignment-measurement aperture situated at the imaging plane, (3) a beam detector situated downstream of the alignment-measurement aperture, and (4) a scanning deflector, situated upstream of the alignment-measurement aperture, configured to impart a deflection in two dimensions to an imaging beam formed of a portion of the illumination beam passing through the aperture-angle-limiting aperture and having a propagation axis. The deflection is transverse to the propagation axis of the imaging beam. The scanning deflector is energized so as to cause the imaging beam to be deflected in the two dimensions over the alignment-measurement aperture, while using the beam detector to obtain an image of beam intensity of the imaging beam passing through the alignment-measurement aperture, as distributed over the two dimensions. In the image of beam intensity a point of maximum intensity, corresponding to the propagation axis of the imaging beam, is identified. Based on the two-dimensional image, the deflector in the illumination-optical system is energized as required to align the propagation axis of the imaging beam with the center of the aperture-angle-limiting aperture. 
     The method can include the step of determining the center of gravity of the aperture-angle-limiting aperture, wherein the center of gravity corresponds to the center of the aperture-angle-limiting aperture. The step of determining the center of gravity of the aperture-angle-limiting aperture can include the steps of: (1) converting the two-dimensional image to a binary image of the aperture-angle-limiting aperture, and (2) from the binary image, determining the center of gravity of the aperture-angle-limiting aperture. 
     The method can include the step of smoothing the two-dimensional intensity distribution, wherein the point of maximum intensity is identified based on the smoothed distribution. 
     According to another aspect of the invention, CPB optical systems are provided. An embodiment of such a system comprises an illumination-optical system situated along an optical axis and including an illumination lens, a deflector, and an aperture-angle-limiting aperture. The illumination-optical system is transmissive to an illumination beam propagating from a beam source. The system also comprises a projection-optical system situated along the optical axis downstream of the illumination-optical system. The projection-optical system includes a projection lens and is transmissive to an imaging beam propagating along a propagation axis from the illumination-optical system. The system also includes a beam-aligmnent device configured to determine a condition of alignment of the propagation axis of the imaging beam with a center of the aperture-angle-limiting aperture. The beam-alignment device comprises: (1) an alignment-measurement aperture situated at an imaging plane; (2) a beam detector situated downstream of the alignment-measurement aperture; (3) a scanning deflector situated upstream of the alignment-measurement aperture, the scanning deflector being configured to deflect the imaging beam in two dimensions, perpendicular to the optical axis, over the alignment-measurement aperture; and (4) a controller connected to the beam detector and the scanning deflector. The controller is configured to (a) energize the scanning deflector so as to deflect the imaging beam (carrying an image of the aperture-angle-limiting aperture) in the two dimensions over the alignment-measurement aperture on the imaging plane, (b) obtain a signal from the beam detector corresponding to a two-dimensional image of intensity of the imaging beam passing through the alignment-measurement aperture, (c) identify a point of maximum intensity corresponding to the propagation axis, and (d) based on the two-dimensional image, energize the deflector in the illumination-optical system as required to align the propagation axis with the center of the aperture-angle-limiting aperture. 
     According to another aspect of the invention, CPB microlithography apparatus are provided that comprise a CPB optical system as summarized above. The CPB microlithography apparatus are not limited to “projection-microlithography” apparatus. Also encompassed are any of various other types of CPB microlithography apparatus, such as CPB point-beam writing apparatus. 
     The foregoing and additional features and advantages of the invention will be more readily apparent from the following detailed description, which proceeds with reference to the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a schematic optical diagram of a charged-particle-beam (CPB) microlithography apparatus, including a CPB optical system, according to a representative embodiment of the invention. 
     FIGS.  2 (A)- 2 (E) schematically depict certain respective steps in a method, according to an aspect of the invention, for determining (from a two-dimensional image) a state of alignment of the propagation axis of the illumination beam with the center of an aperture-angle-limiting aperture, and for performing an alignment of the same. 
     FIG. 3 is a schematic optical diagram of a conventional CPB microlithography apparatus configured to perform an alignment, using conventional methods, of the propagation axis of the illumination beam with the center of an aperture-angle-limiting aperture. 
    
    
     DETAILED DESCRIPTION 
     This invention is described below in the context of a representative embodiment, which is not intended to be limiting in any way. The representative embodiment is described in the context of utilizing an electron beam as the microlithography energy beam. However, it will be understood that any of various other charged particle beams can be used with equal facility, such as an ion beam. The representative embodiment also is described in the context of employing a reticle defining a pattern that is projected onto a sensitive substrate. It will be understood, however, that any of various other types of CPB optical systems and microlithography apparatus (that do not utilize a reticle), such as CPB point-beam writing apparatus, alternatively can be employed. 
     Reference is made to FIG. 1 that schematically depicts an electron-beam projection-microlithography apparatus, and electron-beam optical system, according to the representative embodiment. In FIG. 1, components that are similar to corresponding components shown in FIG. 3 have the same respective reference numerals and are not described further. These similar components are the source  1  (e.g., electron gun with cathode electron-emitting surface), the crossover  2 , the first illumination lens  4 , the beam-shaping aperture  5 , the deflector  6 , the aperture-angle-limiting aperture  7 , the second illumination lens  8 , the reticle  9 , the first projection lens  10 , the second projection lens  11 , and the substrate  12 . The electron beam as emitted by the source  1  is termed the “illumination beam”  3   I , which becomes the “imaging beam”  3   P  after passing through the reticle  9 . The FIG. 1 apparatus also includes an imaging-optical system IOS and a projection-optical system POS. 
     As is typical with CPB projection-microlithography, the reticle  9  defines a pattern that is divided into multiple portions generally termed “exposure units.” An exemplary exposure unit is a “subfield” as understood in the art. In CPB projection-microlithography, rather than exposing the entire pattern, as defined on the reticle, in one “shot,” the individual exposure units are exposed in an ordered manner onto respective regions of the substrate  12  so as to form an image of the complete pattern in which images of the individual exposure units are “stitched” together in a contiguous manner. 
     The FIG. 1 embodiment also includes an alignment-measurement device  18 , described further below, that in this embodiment is located essentially at the substrate  12 . The alignment-measurement device  18  comprises an alignment-measurement aperture  13  situated on the imaging surface  12   a  of the substrate  12 . The imaging surface  12   a  constitutes an “imaging plane” of the projection-optical system POS. The alignment-measurement aperture  13  has a very small diameter but nevertheless is intended to transmit at least a portion of the imaging beam  3   p . Downstream of the alignment-measurement aperture  13  is a scintillator  14  that produces light from impinging charged particles of the imaging beam  3   p . Photons produced by the scintillator  14  are detected by a photomultiplier  15  or analogous detector. For scanning an image, carried by the imaging beam  3   p , of the aperture-angle-limiting aperture  7  over the alignment-measurement aperture  13 , a scanning deflector  16  is situated between the second projection lens  11  and the substrate  12 . 
     The diameter of the alignment-measurement aperture  13  desirably is small compared to the size of the image of the aperture-angle-limiting aperture  7  on the alignment-measurement aperture  13 . The smaller the diameter of the alignment-measurement aperture  13 , the better the achievable locational resolution of the measurement, but the lower the detected beam current and signal-to-noise (S/N) ratio. Hence, the diameter of the alignment-measurement aperture  13  is dictated largely by an optimal balance of locational resolution and S/N ratio. An exemplary diameter is 10 μm, but this figure is not intended to be limiting in any way. 
     As the illumination beam  3   I  propagates downstream of the source  1 , the beam has a “beam axis” or “propagation axis” (not specifically shown but well understood in the art). With a Gaussian illumination beam  3   I , the highest beam current in the transverse intensity profile of the beam normally is at the propagation axis of the beam. The illumination beam  3   I  forms a beam crossover  2 , desirably on the optical axis A just downstream of the source  1 . An image of the cathode is formed on the beam-shaping aperture  5  by the first illumination lens  4 . The beam-shaping aperture  5  typically defines a square or rectangular opening that trims the illumination beam  3   I  passing through the beam-shaping aperture  5 . Thus, the beam-shaping aperture  5  correspondingly defines, as the illumination beam  3   I  passes through the opening, the transverse profile of the illumination beam  3   I  as appropriate for illuminating the desired shape and size of exposure unit on the reticle  9 . 
     Passage of the illumination beam  3   I  through the first illumination lens  4  causes the illumination beam  3   I  to form an image of the beam crossover  2  on the aperture-angle-limiting aperture  7 . The aperture-angle-limiting aperture  7  limits the maximum aperture angle of the imaging beam  3   P  as incident on the substrate  12  or at another suitable imaging plane of the projection-optical system POS. After establishing the desired transverse dimensions of the exposed subfields (or other exposure units) and the desired range of aperture angle, as described above, an image of the cathode is formed on the reticle  9  by the second illumination lens  8 . Pattern resolution is determined largely by two factors. One is aberration, which increases with aperture angle. The other is the Coulomb effect, which decreases with aperture angle. The desirable range of aperture angle (which normally is measured at the imaging plane) is determined by an optimum of these two factors. By way of example, in this embodiment, the aperture angle is 6 mrad at the wafer, but this specific angle is not intended to be limiting in any way. Alternatively to measuring the aperture angle at the imaging plane, the aperture angle can be measured at the object plane (reticle plane in some apparatus) because the object plane is conjugate with the imaging plane. 
     During microlithographic exposure, an image of the reticle  9  (the area of the image being limited by the beam-shaping aperture  5 ) is formed on the upstream-facing “sensitive” surface of the substrate  12  by the first projection lens  10  and second projection lens  12 . 
     For performing an alignment of the propagation axis of the illumination beam  3   I , a region of the reticle  9  is defined to transmit substantially the entire illumination beam  3   I . Alternatively, the reticle  9  can be removed. Charged particles of the imaging beam  3   P  are converged by the first projection lens  10  to form an image of the aperture-angle-limiting aperture  7  on an imaging surface  12   a . The imaging surface  12   a  can be the upstream-facing surface of the substrate  12  or alternatively a region on a wafer stage (not shown but well understood in the art) to which the substrate  12  normally is mounted for exposure. For performing an adjustment of the propagation axis of the imaging beam  3   P , the projection-optical system POS is adjusted so that an image of the aperture-angle-limiting aperture  7  is formed on the alignment-measurement aperture  13 . 
     The portion of the imaging beam  3   P  passing through the alignment-measurement aperture  13  is detected by the scintillator  14  and converted into a respective electrical current by the photomultiplier  15 . A photomultiplier is especially suitable for this task because photomultipliers normally have a response time in nanoseconds and produce a signal gain of several thousand. Additional gain can be produced as required using a post-amplifier (not shown) connected to the photomultiplier  15 . Hence, using the photomultiplier  15 , it is possible to amplify the trace electrical current from the alignment-measurement aperture  13  rapidly. By using a combination of a scintillator  14  and a photomultiplier  15 , the portion of the imaging beam  3   P  passing through the alignment-measurement aperture  13  can be detected with excellent sensitivity and high responsiveness. 
     Meanwhile, the scanning deflector  16  deflects the imaging beam  3   P  (carrying the image of the aperture-angle-limiting aperture  7 ) in a scanning manner over the alignment-measurement aperture  13 . To such end, the scanning deflector  16  is actuated to scan the image of the aperture-angle-limiting aperture  7  two-dimensionally in the X- and Y-directions (the center axis of the projection-lens column is the Z-axis) on the imaging surface  12   a  (imaging plane) over the alignment-measurement aperture  13 . If the instantaneous magnitude of image shift during such scanning is denoted (x,y), then the corresponding instantaneous intensity of the imaging beam  3   P  detected by the alignment-measurement device  18  is denoted A(x,y). The function A(x,y) denotes the two-dimensional (in the X-Y plane) distribution of beam intensity, and is referred to herein as a “two-dimensional” image. The function A(x,y) corresponds to the electron-beam intensity distribution of the aperture-angle-limiting aperture  7  on the imaging plane. 
     In the foregoing description, the X-Y position of an image in two dimensions (X- and Y-dimensions) is determined by operation of the deflector  6  or other beam-scanning appliance. Hence, the distribution of beam intensity, formed after passage of the imaging beam  3   P  through the alignment-measurement aperture  13 , is two-dimensional on the imaging plane. In the two-dimensional image, the revealed location of greatest beam intensity corresponds to the location of the propagation axis of the imaging beam  3   P . Also, because the outline of the two-dimensional image corresponds with the outline of the aperture-angle-limiting aperture  7 , the center of the image corresponds to the center of the aperture-angle-limiting aperture  7 . Hence, by adjusting the deflector  6  to cause the center of the two-dimensional image to be coincident with the location of peak beam intensity, the propagation axis of the beam is aligned accurately with the center of the aperture-angle-limiting aperture  7 . 
     As used herein, “forming a two-dimensional image” is not limited to forming a visible image; it also encompasses forming a set of data that can be used in calculations for determining data otherwise obtainable from a two-dimensional image. Also, processing to determine the outline of a two-dimensional image or the like alternatively can be performed by processing actual data, rather than an image or plot. 
     By determining the two-dimensional distribution of beam intensity based on the intensity profile of the imaging beam  3   P  after passage through the alignment-measurement aperture  13 , the intensity distribution of the beam is determined with high accuracy and precision. Also, since the beam passing through the alignment-measurement aperture  13  is detected directly using a sensor, a better detection signal is obtained than otherwise would be obtained by, according to conventional practice, measuring beam current using an ammeter. 
     FIGS.  2 (A)- 2 (E) schematically depict results of respective steps of a process in which the location of the propagation axis of the beam relative to the center of the aperture-angle-limiting aperture  7  is determined from the two-dimensional image A(x,y). Making such a determination allows the propagation axis of the imaging beam  3   I  and the center of the aperture-angle-limiting aperture  7  to be aligned with each other. FIG.  2 (A) depicts an exemplary initial (mis-aligned) beam-intensity distribution. The distribution is depicted as iso-intensity lines  21  situated relative to the propagation axis  22  of the beam. FIG.  2 (B) depicts the results of converting the data of FIG.  2 (A) into a respective binary image  23 , in which the shaded region denotes regions in which the intensity exceeds a particular threshold. FIG.  2 (C) shows the location of the propagation axis  22  of the beam, as determined from the initial beam-intensity distribution. FIG.  2 (D) depicts shifting of the propagation axis  22  of the beam laterally so as to be coincident with the center  24  of the aperture-angle-limiting aperture  7 . FIG.  2 (E) depicts an aligned condition using iso-intensity lines  21 . Item  24  is the location of the center of gravity of the binary image shown in FIG.  2 (B). 
     In a first step (termed “image processing”) of the alignment process, the two-dimensional image A(x,y) is spatially filtered as required to smooth the two-dimensional image A(x,y). The results of this step are shown in FIG.  2 (A), in which the peak intensity is located at the position  22 , corresponding to the propagation axis of the beam. 
     The two-dimensional distribution of beam intensity in the image A(x,y) actually detected exhibits more fluctuation with increased rate of scanning. Similarly, fluctuations decrease with a corresponding decrease in the scanning rate; this is because, at each measurement point, values are averaged over corresponding longer periods of time. Slower scanning rates are not desired because the time expended to perform an alignment is correspondingly longer. To alleviate the fluctuation phenomenon observed with faster scanning rates, the resulting two-dimensional distribution of beam intensity is “smoothed” to cancel or at least substantially reduce the fluctuations. The location at which beam intensity is greatest is determined using the smoothed data, and the determined location is used as the target position of the propagation axis of the beam. To achieve smoothing of the two-dimensional image, any of various known filter-processing techniques can be used such as any of those conventionally used for image processing. By using smoothed data, the location of the propagation axis of the beam can be determined quite accurately even in situations characterized by increased fluctuations in the intensity distribution due to increased scanning rates. Thus, the time required to perform beam-position alignment is decreased. 
     In a second step, intensity-distribution data, such as shown in FIG.  2 (A), that exceed a specified threshold value are converted to a corresponding binary image. Since the intensity of the charged particle beam can be detected with high resolution, as described above, the image of the aperture-angle-limiting aperture  7  has a sharply outlined profile. This outline can be detected accurately by performing binary-conversion processing or differential processing of the image. By accurately detecting the outline of the aperture  7 , its center of gravity can be determined readily using commonly known methods. 
     In this example, where the outermost iso-intensity line  21  in FIG.  2 (A) represents a threshold, a nearly circular two-dimensional binary image  23  is formed such as shown in FIG.  2 (B). In this step, since an image of the aperture-angle-limiting aperture  7  (which in this example is round) is formed on the imaging surface  12   a , the intensity of the beam changes mostly around the circular edge of the image. Thus, the corresponding binary image in FIG.  2 (B) appears as a round shaded disk. The location of a center of gravity  24  of the binary image can be regarded as the center of the aperture-angle-limiting aperture  7 . Determining the center of gravity  24  from the two-dimensional binary image  23  can be performed using well-known methods, which can be applied with equal facility whether the binary image  23  is round or any other two-dimensional profile. 
     The location  22  at which beam intensity is greatest is determined from an intensity distribution such as that shown in FIG.  2 (A). This location  22  is shown in FIG.  2 (C). The deflector  6  is adjusted as appropriate to move the maximum-intensity position  22  (i.e., the propagation axis of the beam) to be coincident with the center of gravity  24  of the binary image  23  (i.e., the center of the aperture-angle-limiting aperture  7 ), as shown in FIG.  2 (D). This adjustment is performed by calculating the separation distance, in the X- and Y-directions, between the maximum-intensity position  22  and the center of gravity  24 . Then, respective currents are applied to the X-axis deflector and Y-axis deflector components of the deflector  6  to move the point  22  toward the point  24  (FIG.  2 (D)). After making this adjustment, alignment measurements may be performed again as necessary. If misalignment still is evident, then further adjustments using the deflector  6  can be performed as required. 
     In the description above, converting the iso-intensity data to a corresponding binary image was performed as an easy way in which to determine the outline of an image of the aperture-angle-limiting aperture  7 . Alternatively, this determination can be made by differential data processing. Also, whereas FIGS.  2 (A)- 2 (E) schematically depict the results of respective processing steps, as described above, it will be understood that actual data processing in the method is performed by computer calculations and not by drawing figures. 
     Also, in the description above, the location (in the Z-direction) at which the image of the aperture-angle-limiting aperture  7  is formed is the imaging plane  12   a , which normally is coplanar with the upstream-facing surface of the substrate  12  where an image of the reticle  9  is formed during microlithography. Such coincidence is achieved by adjusting the projection-optical system POS. However, it is not necessary that the image of the aperture-angle-limiting aperture  7  be formed at the imaging plane  12   a  using the projection-optical system POS. Alternatively, an image of the aperture-angle-limiting aperture  7  can be formed at any of various imaging planes using a separate dedicated lens system (not shown). However, by using the projection-optical system POS to form the image, the method described above does not require installation or utilization of any additional optical mechanisms other than a blanking aperture and the alignment-measurement device  18 . 
     It is possible to store data concerning the adjustments of the deflector  6  as described above, and to recall the data later for use in a subsequent adjustment. Also, whereas it is possible to perform the alignment adjustments at set intervals, the amount of adjustment required alternatively can be estimated using a function incorporating the cumulative length of time in which the microlithography apparatus has been in continuous use, the beam intensity, etc., and the next adjustment performed when the misalignment exceeds a specified value. 
     Whereas the invention has been described in connection with a representative embodiment, it will be understood that the invention is not limited to that embodiment. On the contrary, the invention is intended to encompass all modifications, alternatives, and equivalents as may be included within the spirit and scope of the invention, as defined by the appended claims.