A method for nondestructively characterizing alignment overlay between two layers
of a semiconductor wafer. An incident beam of radiation is directed upon the wafer
surface and the properties of the resulting diffracted beam are determined, in
one embodiment as a function of wavelength or incident angle. The spectrally or
angularly resolved characteristics of the diffracted beam are related to the alignment
of the overlay features. A library of calculated diffraction spectra is established
by modeling a full range of expected variations in overlay alignment. The spectra
resulting from the inspection of an actual wafer having alignment targets in at
least two layers is compared against the library to identify a best fit to characterize
the actual alignment. The results of the comparison may be used as an input for
upstream and/or downstream process control.