Semiconductors are unique substances, which, under different conditions, can act as either conductors or insulators of electricity. Semiconductor processors turn one of these substances—silicon—into microchips, also known as integrated circuits. These microchips contain millions of tiny electronic components and are used in a wide range of products, from personal computers and cellular telephones to airplanes and missile guidance systems.
To manufacture microchips, semiconductor processors start with cylinders of silicon called ingots. First, the ingots are sliced into thin wafers. Using automated equipment, workers or robots polish the wafers, imprint precise microscopic patterns of the circuitry onto them using photolithography, etch out patterns with acids, and replace the patterns with conductors, such as aluminum or copper. The wafers then receive a chemical bath to make them smooth, and the imprint process begins again on a new layer with the next pattern. A complex chip may contain more than 20 layers of circuitry. Once the process is complete, wafers are then cut into individual chips, which are enclosed in a casing and shipped to equipment manufacturers.
The manufacturing and slicing of wafers to create semiconductors takes place in cleanrooms—production areas that are kept free of all airborne matter because the circuitry on a chip is so small that even microscopic particles can make it unusable. All semiconductor processors working in cleanrooms must wear special lightweight outer garments known as “bunny suits”. These garments fit over clothing to prevent lint and other particles from contaminating the cleanroom.
There are two types of semiconductor processors: operators and technicians. Operators start and monitor the equipment that performs the various production tasks. They spend the majority of their time at computer terminals, monitoring the operation of equipment to ensure that each of the tasks in the production of the wafer is performed correctly. Operators may also transfer wafer carriers from one station to the next, though the lifting of heavy wafer carriers is done by robots in most new fabricating plants.
Technicians are generally more experienced workers who troubleshoot production problems and make equipment adjustments and repairs. They take the lead in assuring quality control and in maintaining equipment. They also test completed chips to make sure they work properly. To keep equipment repairs to a minimum, technicians perform diagnostic analyses and run computations. For example, technicians may determine if a flaw in a chip is due to contamination and peculiar to that wafer, or if the flaw is inherent in the manufacturing process.
To manufacture microchips, semiconductor processors start with cylinders of silicon called ingots. First, the ingots are sliced into thin wafers. Using automated equipment, workers or robots polish the wafers, imprint precise microscopic patterns of the circuitry onto them using photolithography, etch out patterns with acids, and replace the patterns with conductors, such as aluminum or copper. The wafers then receive a chemical bath to make them smooth, and the imprint process begins again on a new layer with the next pattern. A complex chip may contain more than 20 layers of circuitry. Once the process is complete, wafers are then cut into individual chips, which are enclosed in a casing and shipped to equipment manufacturers.
The manufacturing and slicing of wafers to create semiconductors takes place in cleanrooms—production areas that are kept free of all airborne matter because the circuitry on a chip is so small that even microscopic particles can make it unusable. All semiconductor processors working in cleanrooms must wear special lightweight outer garments known as “bunny suits”. These garments fit over clothing to prevent lint and other particles from contaminating the cleanroom.
There are two types of semiconductor processors: operators and technicians. Operators start and monitor the equipment that performs the various production tasks. They spend the majority of their time at computer terminals, monitoring the operation of equipment to ensure that each of the tasks in the production of the wafer is performed correctly. Operators may also transfer wafer carriers from one station to the next, though the lifting of heavy wafer carriers is done by robots in most new fabricating plants.
Technicians are generally more experienced workers who troubleshoot production problems and make equipment adjustments and repairs. They take the lead in assuring quality control and in maintaining equipment. They also test completed chips to make sure they work properly. To keep equipment repairs to a minimum, technicians perform diagnostic analyses and run computations. For example, technicians may determine if a flaw in a chip is due to contamination and peculiar to that wafer, or if the flaw is inherent in the manufacturing process.
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