The method, published in the May 4 issue of Nature Nanotechnology, enables more precise shaping of microchip components than what is possible with current technology. More precise component shapes could help manufacturers build smaller and better microchips, the key to more powerful computers and other devices.

“We are able to achieve a precision and improvement far beyond what was previously thought achievable,” said electrical engineer Stephen Chou, the Joseph C. Elgin Professor of Engineering, who developed the method along with graduate student Qiangfei Xia. Chou’s lab has previously pioneered a number of innovative chip making techniques, including a revolutionary method for making nanometer-scale patterns using imprinting.

Microchips work best when the structures fabricated on them are straight, thin and tall. Rough edges and other defects can degrade or even ruin chip performance in most applications. In integrated circuits, for instance, such flaws could cause current to leak and voltage to fluctuate. In optic devices, they could interfere with the transmission of light. In biological devices, they could impede the flow of DNA and other biomaterials.

“These chip defects pose serious roadblocks to future advances in many industries,” Chou said.

To deal with this problem, researchers try to improve the process used to make the microchips. However, Chou said such an approach works only to a point; eventually chip makers will run up against fundamental physical limits of current manufacturing techniques. In particular, the electrons and photons that are used like chisels to carve out the microscopic features on a chip always have some random behavior. This effect becomes pronounced at very small scales and limits the accuracy of component shapes.

“What we propose instead is a paradigm shift: Rather than struggle to improve fabrication methods, we could simply fix the defects after fabrication,” said Chou. ???And fixing the defects could be automatic — a process of self-perfection.???

Chou’s method, termed Self-Perfection by Liquefaction (SPEL), achieves this by melting the structures on a chip momentarily, and guiding the resulting flow of liquid so that it re-solidifies into the desired shapes. This is possible because natural forces acting on the molten structures, such as surface tension — the force that allows some insects to walk on water — smooth the structures into geometrically more accurate shapes. Lines, for instance, become straighter, and dots become rounder.

Simple melting by direct heating has previously been shown to smooth out the defects in plastic structures. This process can’t be applied to a microchip, for two reasons. First, the key structures on a chip are not made of plastic, which melts at temperatures close to the boiling point of water, but from semiconductors and metals, which have much higher melting points. Heating the chip to such temperatures would melt not just the structures, but nearly everything else on the chip. Secondly, the melting process would widen the structures and round off their top and side surfaces, all of which would be detrimental to the chip.

Chou’s team overcame the first obstacle by using a light pulse from so-called excimer laser, similar to those used in laser eye surgery, because it heats only a very thin surface layer of a material and causes no damage to the structures underneath. The researchers carefully designed the pulse so that it would melt only semiconductor and metal structures, and not damage other parts of the chip. The structures need to be melted for only a fraction of a millionth of a second, because molten metal and semiconductors can flow as easily as water and have high surface tension, which allows them to change shapes very quickly.

To overcome the second obstacle, Chou’s team placed a plate on top of the melting structures to guide the flow of liquid. The plate prevents a molten structure from widening, and keeps its top flat and sides vertical, Chou said. In one experiment, it made the edges of 70 nanometer-wide chromium lines more than five times smoother. The resulting line smoothness was far more precise than what semiconductor researchers believe to be attainable with existing technology.

The conventional approach to fixing chip defects is to measure the exact shape of each defect, and provide a correction precisely tailored to it — a slow and expensive process, Chou said. In contrast, Chou’s guided melting process fixes all defects on a chip in a single quick and inexpensive step. “Regardless of the shape of each defect, it always gets fixed precisely and with no need for individual shape measurement or tailored correction,” Chou said.

One of the big surprises from this work is observed when the guiding plate is placed not in direct contact with the molten structures, but at a distance above it. In this situation, the liquid material from the structures rises up and reaches the plate by itself, causing line structures to become taller and narrower — both highly desirable outcomes from a chip design perspective.

“The authors demonstrate improved edge roughness and dramatically altered aspect ratios in nanoscale features,” said Donald Tennant, director of operations at the NanoScale Science and Technology Facility at Cornell University. The techniques “may be a way forward when nanofabricators bump up against the limits of lithography and pattern transfer,” he said.

Next, Chou’s group plans to demonstrate this technique on large (8-inch) wafers. Several leading semiconductor manufacturers have expressed keen interest in the technique, Chou said.

[Steven Schultz @ Princeton University Engineering School]

The dime-sized laser, to be described Thursday, May 8, at the Conference on Lasers and Electro-Optics, emits 10 billion pulses per second, each lasting about 40 femtoseconds (quadrillionths of a second), with an average power of 650 milliwatts. For comparison, the new laser produces pulses 10 times more often than a standard NIST frequency comb while producing much shorter pulses than other lasers operating at comparable speeds. The new laser is also 100 to 1000 times more powerful than typical high-speed lasers, producing clearer signals in experiments. The laser was built by Albrecht Bartels at the Center for Applied Photonics of the University of Konstanz.

Among its applications, the new laser can be used in searches for planets orbiting distant stars. Astronomers look for slight variations in the colors of starlight over time as clues to the presence of a planet orbiting the star. The variations are due to the small wobbles induced in the star’s motion as the orbiting planet tugs it back and forth, producing minute shifts in the apparent color (frequency) of the starlight. Currently, astronomers’ instruments are calibrated with frequency standards that are limited in spectral coverage and stability. Frequency combs could be more accurate calibration tools, helping to pinpoint even smaller variations in starlight caused by tiny Earthlike planets. Such small planets would cause color shifts equivalent to a star wobble of just a few centimeters per second. Current instruments can detect, at best, a wobble of about 1 meter per second.

Standard frequency combs have “teeth” that are too finely spaced for astronomical instruments to read. The faster laser is one approach to solving this problem. In a separate paper, the NIST group and astronomer Steve Osterman at the University of Colorado at Boulder describe how, by bouncing the light between sets of mirrors a particular distance apart, they can eliminate periodic blocks of teeth to create a gap-toothed comb. This leaves only every 10th or 20th tooth, making an ideal ruler for astronomy.

Both approaches have advantages for astronomical planet finding and related applications. The dime-sized laser is very simple in construction and produces powerful and extremely well-defined comb teeth. On the other hand, the filtering approach can cover a broader range of wavelengths. Four or five filtering cavities in parallel would provide a high-precision comb of about 25,000 evenly spaced teeth that spans the visible to near-infrared wavelengths (400 to 1100 nanometers), NIST physicist Scott Diddams says.

Osterman says he is pursuing the possibility of testing such a frequency comb at a ground-based telescope or launching a comb on a satellite or other space mission. Other possible applications of the new laser include remote sensing of gases for medical or atmospheric studies, and on-the-fly precision control of high-speed optical communications to provide greater versatility in data and time transmissions. The application of frequency combs to planet searches is of international interest and involves a number of major institutions such as the Max-Planck Institute for Quantum Optics and Harvard Smithsonian Center for Astrophysics.

[Laura Ost @ National Institute of Standards and Technology (NIST)]

Denise Jackson had such success with her first book that she was inspired to write another. via WBIR-TV

Berkeley Lab has signed a collaboration agreement with Tensilica, Inc. to explore the use of Tensilica’s Xtensa processor cores as the basic building blocks in a massively parallel system design. Tensilica’s Xtensa processor is about 400 times more efficient in floating point operations per watt than the conventional server processor chip shown here.

In a paper published in the May issue of the International Journal of High Performance Computing Applications, Michael Wehner and Lenny Oliker of Berkeley Lab’s Computational Research Division, and John Shalf of the National Energy Research Scientific Computing Center (NERSC) lay out the benefit of a new class of supercomputers for modeling climate conditions and understanding climate change. Using the embedded microprocessor technology used in cell phones, iPods, toaster ovens and most other modern day electronic conveniences, they propose designing a cost-effective machine for running these models and improving climate predictions.

In April, Berkeley Lab signed a collaboration agreement with Tensilica, Inc. to explore such new design concepts for energy-efficient high-performance scientific computer systems. The joint effort is focused on novel processor and systems architectures using large numbers of small processor cores, connected together with optimized links, and tuned to the requirements of highly-parallel applications such as climate modeling.

Understanding how human activity is changing global climate is one of the great scientific challenges of our time. Scientists have tackled this issue by developing climate models that use the historical data of factors that shape the earth’s climate, such as rainfall, hurricanes, sea surface temperatures and carbon dioxide in the atmosphere. One of the greatest challenges in creating these models, however, is to develop accurate cloud simulations.

Although cloud systems have been included in climate models in the past, they lack the details that could improve the accuracy of climate predictions. Wehner, Oliker and Shalf set out to establish a practical estimate for building a supercomputer capable of creating climate models at 1-kilometer (km) scale. A cloud system model at the 1-km scale would provide rich details that are not available from existing models.

To develop a 1-km cloud model, scientists would need a supercomputer that is 1,000 times more powerful than what is available today, the researchers say. But building a supercomputer powerful enough to tackle this problem is a huge challenge.

Historically, supercomputer makers build larger and more powerful systems by increasing the number of conventional microprocessors — usually the same kinds of microprocessors used to build personal computers. Although feasible for building computers large enough to solve many scientific problems, using this approach to build a system capable of modeling clouds at a 1-km scale would cost about $1 billion. The system also would require 200 megawatts of electricity to operate, enough energy to power a small city of 100,000 residents.

In their paper, Towards Ultra-High Resolution models of Climate and Weather, the researchers present a radical alternative that would cost less to build and require less electricity to operate. They conclude that a supercomputer using about 20 million embedded microprocessors would deliver the results and cost $75 million to construct. This “climate computer” would consume less than 4 megawatts of power and achieve a peak performance of 200 petaflops.

“Without such a paradigm shift, power will ultimately limit the scale and performance of future supercomputing systems, and therefore fail to meet the demanding computational needs of important scientific challenges like the climate modeling,” Shalf said.

The researchers arrive at their findings by extrapolating performance data from the Community Atmospheric Model (CAM). CAM, developed at the National Center for Atmospheric Research in Boulder, Colorado, is a series of global atmosphere models commonly used by weather and climate researchers.

The “climate computer” is not merely a concept. Wehner, Oliker and Shalf, along with researchers from UC Berkeley, are working with scientists from Colorado State University to build a prototype system in order to run a new global atmospheric model developed at Colorado State.

“What we have demonstrated is that in the exascale computing regime, it makes more sense to target machine design for specific applications,” Wehner said. “It will be impractical from a cost and power perspective to build general-purpose machines like today’s supercomputers.”

Under the agreement with Tensilica, the team will use Tensilica’s Xtensa LX extensible processor cores as the basic building blocks in a massively parallel system design. Each processor will dissipate a few hundred milliwatts of power, yet deliver billions of floating point operations per second and be programmable using standard programming languages and tools. This equates to an order-of-magnitude improvement in floating point operations per watt, compared to conventional desktop and server processor chips. The small size and low power of these processors allows tight integration at the chip, board and rack level and scaling to millions of processors within a power budget of a few megawatts.

Berkeley Lab is a U.S. Department of Energy national laboratory located in Berkeley, California. It conducts unclassified scientific research and is managed by the University of California. Visit our Website at www.lbl.gov.

[Ucilia Wang @ DOE/Lawrence Berkeley National Laboratory]

“People concerned with the effects of gas prices were significantly less attentive on the job, less excited about going to work, less passionate and conscientious and more tense,” Hochwarter said. “These people also reported more ‘blues’ on the job. Employees were simply unable to detach themselves from the stress caused by escalating gas prices as they walked through the doors at work.”

Hochwarter gleaned the information by surveying more than 800 full-time employees this spring when gas prices hovered at about $3.50 per gallon. All of the people surveyed work in a wide range of occupations, primarily in the southeastern United States. All drove personal transportation to work and had an average commute of 15 miles each way.

Survey respondents said gas prices were foremost on their mind, including a disgruntled factory worker who wrote, “I spend more time at work trying to figure out what I need to give up to keep gas in my tank than thinking about how to do my job.”

Hochwarter’s research will be submitted for publication later this summer. Among his findings:

• 52 percent have reconsidered taking vacations or other recreational activities

• 45 percent have had to cut back on debt-reduction payments, such as credit card payments
• Nearly 30 percent considered the consequences of going without basics including food, clothing and medicine
• 45 percent report that the escalating gas prices have “caused them to fall behind financially”
• 39 percent agreed with the statement “Gas prices have decreased my standard of living”
• About 33 percent — or one in three — said they would quit their job for a comparable one nearer to home

Hochwarter’s discussions with employees confirm the study’s results. Many employees report that gas prices rank as the No. 1 water-cooler discussion topic, ahead of family, sports or work, he said. He found little difference in responses among different ages, gender, work tenure and occupations.

“Several employees said they simply could not escape the media onslaught of bad news regarding the future of gas prices, and many reported their financial futures were looking bleaker and bleaker,” Hochwarter said.

As gas prices rise, so does the stress. Consider the words of Sandy, a medical records clerk: “The more it goes up, the more behind I get. If gas goes up to $5 or $6 a gallon, I just don’t know what I’ll do.”

[Wayne Hochwarter @ Florida State University]