Apparatus and method for batch non-contact material characterization

An apparatus for performing non-contact material characterization includes a wafer carrier adapted to hold a plurality of substrates and a material characterization device, such as a device for performing photoluminescence spectroscopy. The apparatus is adapted to perform non-contact material characterization on at least a portion of the wafer carrier, including the substrates disposed thereon.

BACKGROUND OF THE INVENTION

Various non-contact material characterization techniques are known and are commonly used to measure semiconductor wafers. Non-contact material characterization techniques include: X-ray diffraction (“XRD”), eddy current measurements, and photoluminescence spectroscopy, among others. Photoluminescence spectroscopy, for example, is a technique wherein light is directed from a pump beam onto a sample, such as a semiconductor wafer. Such light may first be absorbed by the material and then dissipated, such as through emission of light (also known as “luminescence”). By measuring the intensity and spectral content of the luminescence by means of collection optics, various important material properties may be gleaned. Such properties revealed by photoluminescence include: determination of band gap, material quality (including the concentration of impurities and defects), composition of the different semiconductor layers, among many other properties. One useful way of analyzing the data may include plotting photoluminescence intensity as a function of wavelength. The full width at half maximum (“FWHM”) may then be measured and plotted.

Currently, such material characterization techniques are performed outside of the epitaxial growth apparatus in which the semiconductor wafers are formed. Commonly, the wafers are removed from the epitaxial growth apparatus and placed into cassettes of wafers. The cassettes are then cycled through, and the non-contact material characterization techniques are conducted on a wafer-by-wafer basis, with one wafer being tested at a time. This process can take a considerable amount of time.

Further adding to current processing times is the fact that typical processing apparatuses utilize a chamber referred to as a “load lock” in addition to the principal process chamber. A substrate, or a wafer carrier holding numerous substrates, is inserted into the load lock and brought to equilibrium with an inert atmosphere in the load lock compatible with the epitaxial growth process. Once the substrates are at equilibrium with the inert atmosphere in the load lock, a door between the load lock and the process chamber itself is opened, and the substrates are advanced into the process chamber. After processing, the substrates are removed from the process chamber through the load lock. Multiple handling into and out of the epitaxial growth apparatus takes considerable time, which in turn, slows the process.

With regard to photoluminescence techniques, for example, the wafers are typically placed on a stage and the pump beam and collection optics are either moved in a raster-scan or an outwardly spiraling pattern. That is, in the case of a raster-scan, the pump beam and collection optics are moved linearly across the surface in a first direction from one end of the wafer to the other. After fully scanning a first line across the wafer, the pump beam and collection optics are moved a small, incremental distance perpendicular to the first direction, and then they proceed to linearly scan across the surface parallel to and adjacent to the first line. This process is repeated until the entire surface of the wafer has been scanned. This technique is analogous to, for example, reading lines of text across the surface of a page from left to right and incrementally moving from the top line to the bottom. In the case of an outwardly spiraling pattern, however, the pump beam and collection optics begin scanning at the center of the wafer, and then they proceed to spiral outwardly from the center until the entire surface of the wafer has been scanned.

The above described prior art method of performing non-contact material characterization techniques can be very inefficient. Particularly in the case where multiple processes are to be performed on a group of semiconductor wafers, with material characterization occurring between each process, it can take a substantial amount of time to complete the overall process. Specifically, it can be very time consuming to first remove all of the wafers from the epitaxial growth apparatus after one process is completed, then to perform the testing on each wafer one at a time, and then to reseat the wafers on a wafer carrier and introduce the wafers to the same or a different apparatus for further processing.

BRIEF SUMMARY OF THE INVENTION

One aspect of the present invention provides an apparatus for performing non-contact material characterization on substrates. The apparatus in accordance with this aspect of the invention desirably includes a wafer carrier and a non-contact material characterization device. The wafer carrier desirably has a top surface constructed and arranged to hold at least one substrate thereon. The non-contact material characterization device is desirably constructed and arranged to perform a non-contact material characterization technique on at least a portion of at least one substrate held on the wafer carrier.

The apparatus may further include an epitaxial growth apparatus having a load lock. The non-contact material characterization device is desirably constructed and arranged to perform the non-contact material characterization technique while the wafer carrier is disposed within the load lock of the epitaxial growth apparatus.

A computational device may be connected to the non-contact material characterization device and connected to an epitaxial growth apparatus. The computational device is preferably constructed and arranged to process data from the non-contact material characterization device. Further, the computational device may be operative to adjust conditions in the epitaxial growth apparatus based on the data processed by the computational device.

The non-contact material characterization device may comprise a device for performing photoluminescence spectroscopy.

Still other aspects of the present invention provide methods for performing non-contact material characterization on substrates.

DETAILED DESCRIPTION

In describing the preferred embodiments of the invention illustrated in the appended drawings, in which like reference numerals represent like elements, specific terminology will be used for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents that operate in a similar manner to accomplish a similar purpose.

An apparatus in accordance with one embodiment of the invention is illustrated inFIG. 1. A wafer carrier10is shown holding a plurality of substrates, such as wafers12. The wafers12are preferably held by structures such as pockets (not shown). The wafer carrier10is preferably generally circular in shape, although this is not required, and the carrier10is preferably composed of a material such as graphite.

The wafer carrier10is shown mounted on a spindle14, which may rotate about axis15under the influence of a rotation control device, such as motor16. The motor16is preferably connected to a control device18, which will be discussed in detail below. The motor16is preferably adapted to precisely control the angular position and rotational velocity of the wafer carrier10. Useful motors16for this application may include stepper motors and servos, for example.

The connection (not shown) between the spindle14and the wafer carrier10is designed so that the wafer carrier10may releasably mate with the spindle14. The connection is preferably configured so that the wafer carrier10may be secured to the spindle14in such a way that the wafer carrier10and spindle14may rotate in a fixed angular relationship. The connection is also preferably configured to allow the wafer carrier10to be easily detached from the spindle14, so that the wafer carrier10can be moved.

As schematically shown inFIG. 2, the wafer carrier10is shown in the load lock102of an epitaxial growth chamber100. The load lock102is equipped with a chamber door104and an exterior door106. When the chamber door104is opened, the interior space within load lock102communicates with the interior space of the epitaxial growth chamber100. When door104is closed, the load lock102is isolated from the epitaxial growth chamber100. When door106is open, the load lock102is open to the exterior of the apparatus, and most typically, is open to room air. The interior space within load lock102is connected to a source of a substantially inert gas, so that the interior space within the load lock102may be maintained under an atmosphere of the substantially inert gas. As used in this disclosure, the term “substantially inert gas” refers to a gas which does not cause substantial, detrimental reactions with the substrates or layers disposed on the substrates under the conditions prevailing in the load lock. Merely by way of example, for typical substrates carrying layers of III-V semiconductors, gases such as nitrogen, hydrogen, group VIII noble gases, and the like, and mixtures of these gases can be employed.

A conveyor (not shown) may be provided within the load lock102, the conveyor being configured to move the wafer carrier10into or out of the epitaxial growth chamber100while the chamber door104is open. The conveyor may include any type of mechanical element capable of manipulating the wafer carrier10, such as, for example, robotic arms, linear slides, pick-and-place mechanisms, mobile chains or belts, or combinations of these elements.

During a preferred use of the apparatus of the present invention, the following steps are carried out in order to perform a non-contact material characterization technique on the wafers12. After one cycle of epitaxial growth processing is completed on the wafers12, the door104is opened and the wafer carrier10is detached from spindle116. The carrier10is then moved from the epitaxial growth chamber100into the load lock102by the conveyor. The carrier10is then mated to the spindle16. While the wafer carrier10is thus disposed within the load lock102, at least one non-contact material characterization technique is performed, as described in detail below.

It is to be noted that by performing non-contact material characterization measurements while the wafer carrier10is in the load lock102, overall processing time for the substrates will preferably be reduced. Specifically, the amount of time required to move the carrier10into and out of the load lock102through door106in order to perform tests on the substrates is eliminated. Also eliminated is the additional time required allow the atmosphere in the load lock102to reach equilibrium, since the wafer carrier10is not required to be removed from the load lock102during testing and the exterior door106is not required to be opened.

A further benefit of performing the material characterization technique in the load lock102is the fact that information gathered from the testing can be used to control one or more of the processes. For example, the information gathered can be processed by a programmed computational device integrated with the epitaxial growth apparatus. The computational device may be connected to or incorporated with the control device18. The computational device is preferably integrated with the epitaxial growth apparatus in such a way that, based on the information gathered by the computational device, the conditions in the growth chamber100may be adjusted to optimize the conditions for a subsequent set of substrates. Alternatively or additionally, the computational device may use the information obtained by the non-contact measurement to adjust the process to be applied to the substrates on this particular carrier10in a subsequent step, as for example, during further treatment in process chamber100or in a different process chamber.

In a typical epitaxial growth apparatus, the wafers12are first removed from the epitaxial growth apparatus, and then they are tested in a remote lab, after which the data from the testing may be used to optimize the conditions in the growth chamber. The time it takes to perform those steps creates significant “loop delay,” as several processes may have been performed in the growth chamber under the previous process conditions before the conditions are modified based on the material characterization tests. In contrast, by performing the material characterization techniques in the load lock102and, thus, quickly providing information to control subsequent processes, the apparatus of the present invention reduces any such “loop delay.”

The mechanisms for conducting non-contact material characterization in accordance with a preferred embodiment of the invention will now be discussed. Referring again toFIG. 1, shown mounted above the wafer carrier10is a non-contact material characterization device, such as, for example, a photoluminescence device20. The photoluminescence device20may include a pump beam emitter22and collection optics24. The pump beam emitter22may be configured to project a precisely defined beam of light at the top surface40of the wafer carrier10, so that the light may either reflect back to the collection optics24or so that the luminescence of the material at the top surface40of the carrier10may be measured by the collection optics24.

The photoluminescence device20is preferably configured to precisely control the frequency of the emitted beam of light. Precise control over the various parameters of the photoluminescence system, such as frequency of the emitted light, will preferably make the entire system more accurate. Furthermore, frequency of the light emitted from the pump beam emitter22may be varied in order to target different layers of the semiconductor for analysis. That is, because different layers in a semiconductor having different band gaps will absorb different frequencies of light, the different layers of the semiconductor may be targeted for analysis by selecting the appropriate frequency of light to be absorbed by that layer.

The photoluminescence device20as described above is per se a conventional device.

The device20, in accordance with a preferred embodiment of the present invention, is preferably mounted to a translation mechanism30which operates to translate the photoluminescence device20along a guiding apparatus, such as a guiding rail32. The translation mechanism30may comprise any known mechanism for translating a device in at least one dimension. Appropriate translation mechanisms30may include, for example, linear actuators, belt drives, screw drives, etc.

The translation mechanism30and guiding rail32are preferably arranged so that the photoluminescence device20may scan at least a portion of the wafer carrier10. In the embodiment illustrated inFIG. 1, the translation mechanism30and guiding rail32are arranged so that the photoluminescence device20may translate back and forth in one dimension across the top surface40of the wafer carrier10. Specifically, in the illustrated embodiment, the photoluminescence device20preferably scans the top surface40radially with respect to axis15, moving between the center42and the outer edge44of the wafer carrier10. In this way, the device20may scan the entire top surface40of the wafer carrier10. That is, the photoluminescence device20may scan a line across the top surface40from, for example, the center42of the wafer carrier10in a radial direction to the edge44. Once the device20reaches the edge44, the motor16preferably rotates the wafer carrier10about axis15by a small degree increment. The device20then scans again, for example, from the edge44to the center42. This process is repeated, with the position of the wafer carrier10being incrementally rotated with each pass of the photoluminescence device20until a complete revolution of the wafer carrier10has been made.

During the above-described movement of the photoluminescence device, while the pump beam emitter22projects light at the top surface40of the wafer carrier10, the collection optics24measure the luminescence of the target portion of the material. The information received by the collection optics24may include data such as intensity and wavelength of the collected light. This data is collected as a series of samples representing the measured values of each variable corresponding to each discrete sampled location on the top surface40of the wafer carrier10. By taking samples at many discrete locations (which are very close to each other), the entire top surface40of the wafer carrier10, including the top surfaces of the wafers12, may be accurately mapped.

The data collected from the photoluminescence device20is preferably stored in a memory device46, which may be a component of the control device18. The data is preferably associated with the geometrical position of each sampled point P. The position of each point P may be described in many ways, such as Cartesian coordinates. In one embodiment, however, the location of each sample point P may be described by that point's radial coordinates about axis15. In order to define radial coordinates, the wafer carrier10preferably has a reference axis50extending from the center42of the wafer carrier10. Thus, each point P may be defined by its radial distance R from the center42of the wafer carrier10and by its angle θ from the reference axis50.

After completing a scan of the wafer carrier10, the memory device46will preferably have all of the photoluminescence data regarding the top surface40. The memory device46also preferably contains information regarding the geometry of the wafer carrier10, including the relationships of the pockets (which hold the wafers12) to reference axis50and the radial distances of such pockets from center42. From this data, information regarding each semiconductor wafer12may be calculated. That is, by coordinating the input data with its corresponding radial coordinates, and by comparing the coordinates to stored information regarding the geometry of the wafer carrier10, the control device18may correctly link the data from each photoluminescence measurement with the appropriate wafer12and with a particular location on the wafer12.

In this embodiment of the apparatus of the present invention, a control device18is designed to fully operate all components of the apparatus. That is, the control device18may be adapted to control the movement of the motor16. The control device18is also preferably configured to control the movement of the photoluminescence device20, by providing appropriate signals to the translation mechanism30. Further, the control device18preferably controls the photoluminescence device20itself, including the pump beam emitter22, and the intensity and frequency of the light emitted therefrom. The control device18also preferably receives and processes the input from the collection optics24, as described above. The control device18may include a programmed general purpose computer or a portion of such a computer, or may include plural computational elements physically separate from one another but connected to one another.

The apparatus as described above will preferably speed up the overall processing time for substrates, such as semiconductor wafers12. In addition to eliminating the time required to remove the wafers12from the load lock102for testing, as described above, the apparatus of the present invention may further increase efficiency by processing multiple wafers12in batches. That is, the apparatus is preferably constructed to scan the entire top surface40of a wafer carrier10holding many wafers12, rather than scanning each wafer12one at a time.

Many alternatives to the preferred embodiment are encompassed by the present invention, not all of which are described herein. For example, though the above-described reference axis50is preferably one defined by the motor16, in an alternative embodiment there may be a rotary encoder (not shown) connected to the spindle14, which provides data to the control device18regarding the angle θ. Alternatively, a physical axis or mark52on the top surface40of the wafer carrier10may define the axis50. Such mark52is preferably observable by the photoluminescence device20, such as by constructing it of a material having known photoluminescent properties. In that way, the control device18may be able to deduce the radial orientation of the wafer carrier10after completing the full scan of the surface40and aligning the data with the observed reference axis50. In a further alternative, no physical mark52need be present, and the geometry of the top surface40of the wafer carrier10may be rotationally asymmetric, such as, for example, by having at least one gap between the wafer pockets be larger than the others. In this embodiment, the data from the complete scan of the top surface40may be compared to known information about the geometry of the wafer carrier10, and the control device18may accordingly deduce the rotational coordinates of each sample point P and assign the correct data to the appropriate wafers12. By constructing the wafer carrier10of material having no photoluminescent properties, the control device18will be able to distinguish between the wafers12and the carrier10, and the device28will be able to assign the correct data to the appropriate wafers12accordingly.

Further, the present invention is not limited to the above-described manner of scanning the surface40of the wafer carrier10. Alternative methods may be employed consistent with the present invention. For example, the photoluminescence device20may scan the surface40by scanning in concentric circles. For instance, the beam from the photoluminescence device20may start at the center42of the wafer carrier10and step out one increment in a radial direction. The device20may then scan while the motor16fully rotates the wafer carrier10once about axis15. The device20may then step out again and the carrier10may be rotated once again. This process may be continued until the entire top surface has been scanned. In a similar alternative, the device20may perform an outwardly spiraling scan by gradually moving radially outwardly from the center42while the wafer carrier10continuously rotates.

In a further alternative embodiment, the translation mechanism30and guiding rail32may be arranged so that the photoluminescence device20may translate in two dimensions across the top surface40of the wafer carrier10. For instance, the guiding rail32may be mounted on another device, such as a second guiding rail (not shown), which is configured to translate along an axis perpendicular to the guiding rail32. In accordance with such an embodiment of the invention, the wafer carrier10may be scanned by, for example, moving the photoluminescence device20in a raster-scan, an outwardly spiraling pattern, or a concentric circle pattern, as described above, over the entire top surface40of the carrier10.

In a further alternative embodiment, the translation mechanism30may be replaced by a different means for moving a beam of radiant energy across the surface of the wafer carrier, such as a pivoting mechanism, which may move the beam of light around by pivoting in one or two dimensions.

It is to be further noted that the present invention is not limited to locating the non-contact material characterization device, such as the photoluminescence device20, in a position directly above the wafer carrier10. Alternative arrangements of the device20may be used. For example, a mirror or other optical device may be attached to the translating mechanism30instead of the photoluminescence device20. In such an embodiment, the photoluminescence device20may be disposed in a location remote from the optical device, where it may be configured to project the beam of light towards and receive the reflected light back from the optical device. The optical device may then redirect such beams of light towards the top surface40of the wafer carrier10. Then, by translating the optical device in the manner described above with respect to the photoluminescence device20, the top surface40of the wafer carrier10may be similarly scanned without requiring the photoluminescence device20itself to be translated. Such optical device may similarly pivot instead of translating, as described above.

In a further alternative, an apparatus in accordance with the present invention need not be incorporated with load lock102. Instead, the apparatus may be located in and incorporated with a transfer chamber, such as that shown and described in U.S. Provisional Application No. 61/066,031 filed Feb. 15, 2008, and entitled “Cluster Tool and Process for III-V Materials” [hereinafter “the Cluster Tool application”], the entire disclosure of which is fully incorporated by reference herein. The transfer chamber of the Cluster Tool application is a chamber in communication with a plurality of adjacent process chambers. As described in such application, such a configuration may be beneficially used where multiple different processes, each having different process chambers, are to be performed on a substrate. In order to speed up the overall process time on such substrate, the transfer chamber may be adapted to provide an inert atmosphere through which the substrate may be transferred from one process chamber to another. In accordance with the present invention, it may further speed up the overall process time on the substrate to incorporate the apparatus of the present invention into such transfer chamber, where it may be configured to perform non-contact material characterization on the wafer carrier10while it is located in the transfer chamber.

An example of such a transfer chamber is shown inFIG. 3, which illustrates a plurality of processing chambers210,212,214,216,218, and220, and a transfer chamber222. The processing chambers210-220are physically connected to the transfer chamber222so that the interior space within each processing chamber can communicate with the transfer chamber. Each processing chamber210-220is equipped with a door224arranged to selectively permit or block such communication. For example, in the condition depicted inFIG. 3, the doors224associated with chambers210,212,214, and216are in their respective closed positions, whereas the doors224associated with chambers218and220are in their open positions so that the interior spaces within chambers218and220are in communication with the interior of transfer chamber222. Each processing chamber is arranged to receive a carrier226holding a plurality of growth substrates228such as flat wafers of a crystalline material, and to perform a process on the substrates while the substrates are disposed within the processing chamber. The individual processing chambers are arranged to perform different processes. For example, chamber210is arranged to perform a hydride vapor phase epitaxial growth process (referred to herein as “HVPE”), process chambers212and214are arranged for MOCVD, and additional reaction chambers216,218, and220are equipped to perform other processes. Merely by way of example, these other processes may include deposition of metals to serve as conductors; epitaxial growth by processes such as molecular beam epitaxy, atomic layer epitaxy, or the like; etching of the substrates or of layers deposited on the substrates; or any other process which can be applied to a substrate, with or without compound semiconductor thereon. Each such chamber desirably is optimized for the particular process or processes to be performed therein.

The apparatus also includes load locks248and250. Load lock248is equipped with a transfer chamber door252and an exterior door254. Load lock250is equipped with a similar transfer chamber door256and exterior door258. The interior space within transfer chamber222is connected to a source260of a substantially inert gas, so that the interior space within the transfer chamber222may be maintained under an atmosphere of the substantially inert gas. The substantially inert gas may be the same as, or different from, the carrier gases employed in one or more of the reaction chambers, and hence source260may be combined with one or more of the other carrier gas sources. Load locks248and250desirably are also connected a source of a substantially inert gas, which may be the same source260or a different source.

A conveyor262is also provided within transfer chamber222. The conveyor is schematically depicted inFIG. 1as an arm capable of moving in circumferential directions around a central axis264and radial directions towards and away from the axis. In other embodiments, the conveyor may include any type of mechanical element capable of manipulating carriers226, as for example, elements such as linear slides, pick-and-place mechanisms, mobile chains or belts, or combinations of these elements. Also, the circular shape of transfer chamber222depicted inFIG. 3is merely illustrative. Conveyor262is arranged so that it can move wafer carriers into or out of any of the process chambers210-220while the associated doors224of these chambers are open. The conveyor also can move wafer carriers into or out of load locks248and250when doors252and256are open. The conveyor is arranged so that it can transfer carriers226between the various chambers, as for example, out of either of the load locks into any of the process chambers, or out of any of the process chambers into any other process chamber or into any of the load locks. Conveyor262may be arranged to move every wafer in the same sequence, so that every wafer carrier will be moved through the same set of process chambers in the same order. More preferably, however, conveyor262is controlled by a programmable or selectively operable mechanism, as for example, one or more electrical, mechanical, or hydraulic components linked to one or more programmable controllers, so that the sequence of movements between chambers can be varied, either for different process runs or for individual wafers within a process run.

The transfer chamber also may be provided with one or more non-contact material characterization devices266, arranged to direct one or more beams of radiant energy to or through substrates228held on a carrier226while the carrier is disposed within the transfer chamber, and to monitor one or more properties of the substrates or materials deposited on the substrates based on interactions between the radiant energy and the substrate. The transfer chamber may be equipped with a stand schematically depicted at268inFIG. 3for holding a wafer carrier226with substrates228thereon, and apparatus for moving the beam from the non-contact material characterization device266, the substrates, or both, so that the substrates move relative to the beam, and the beam passes over different areas of the various substrates held on a carrier226. The movement apparatus may include, for example, a support linked to a mechanical motion apparatus which can rotate the support268, and hence, the wafer carrier about the axis of the wafer carrier. The movement apparatus may be arranged to translate the wafer carrier in directions transverse to its axis. The movement apparatus also may include apparatus for moving one or more components of the non-contact material characterization device, so as to move the beam of radiant energy. Merely by way of example, the non-contact material characterization device may include a beam-directing element270such as a mirror, lens, holographic element, or the like, and the movement apparatus may be arranged to move the beam-directing element270, so as to move the beam. Where the non-contact material characterization device is arranged to receive radiation from the substrate, as for example, in a photoluminescence measurement, the movement device similarly moves the field of view of the non-contact material characterization device. One or both of the load locks248,259may be equipped with a similar non-contact material characterization apparatus272.

In a method according to one embodiment of the invention, as the substrates are moved between the chambers, properties of the substrates, or the layers being grown thereon, can be monitored using the non-contact material characterization device266. The information gathered in this manner can be used to control one or more of the processes. For example, a substrate removed from HVPE process chamber10can be conveyed to the stand268and monitored using the non-contact material characterization device266. The information gathered in this process can be used to optimize conditions in the HVPE process chamber210for a subsequent set of substrates. Alternatively or additionally, the information obtained by the non-contact material characterization can be used to adjust the process to be applied to the substrates on this particular carrier in a subsequent step, as for example, during treatment in MOCVD process chamber212.

It is appreciated that various means for moving the beam of radiant energy from the photoluminescence device20across the surface40of the wafer carrier10have been disclosed herein. Such means include the one or two dimensional translation mechanism30, discussed above, or the alternative pivoting mechanism. Other such means include the movement apparatus described in connection with the transfer chamber222.

It is to be further noted that, though the above described embodiments of the present invention have been described in combination with a specific non-contact material characterization technique, namely photoluminescence spectroscopy, the present invention is not limited to the use of such technique. Any other non-contact material characterization technique may be used in conjunction with the apparatus of the present invention. For example, non-contact surface curvature measurements may be made by directing a beam of light onto a surface of a wafer12and detecting the position of the reflected beam. Such a surface curvature measurement technique is shown and described in, for example, pending U.S. application Ser. No. 11/127,834 (“the '834 application”), filed May 12, 2005, Pub. No. 2005/0286058, and entitled “Method and Apparatus for Measuring the Curvature of Reflective Surfaces,” the entire disclosure of which is fully incorporated by reference herein.

The apparatus of the present invention is also not limited to performing non-contact material characterization techniques after a cycle of epitaxial growth processing is completed. The apparatus may also perform a pre-run check of the wafers12while the wafer carrier10is in the load lock102, or the transfer chamber, and before the wafer carrier10is moved into an epitaxial growth chamber100for processing. For example, a non-contact material characterization device in accordance with the present invention may include a deflectometer, which may operate similarly to the non-contact surface curvature measurement apparatus described in the '834 application. Specifically, such deflectometer may direct a beam of light onto a surface of a wafer12and detect the position of the reflected beam. If the position of the reflected beam deviates from its expected position, it may indicate that the wafer12is not sitting properly on the carrier10. This may occur, for example, when a particle is underneath the wafer12when it is loaded on the wafer carrier10, and the wafer12is not sitting parallel to the carrier10as a result. It would be beneficial to obtain this information before processing is conducted on the wafers12, because non-parallel seating will likely cause non-uniform thermal transfer to the wafers12during processing.

Furthermore, it is contemplated that material characterization techniques involving physical contact with the wafers12may also be performed consistent with the present invention. For example, the above-described photoluminescence device20may be replaced with a device having a probe that is configured to extend to the surface40of the wafer carrier10, where it tests the material in contact therewith. Such device may be mounted to a translation mechanism30, as described above, which may similarly move the probe so that it may scan the entire surface40of the wafer carrier10.