Taiwan Semiconductor Manufacturing Comp. Ltd.

Hong Pin Lin

Hsu Ming Hsiao

Che-fu Chen

Shiang-Bau Wang

Yi-Jen Chen

An Chyi Wei

Ming-Jhe Sie

Hsiu-Hao Tsao

Kung Shu Hsu

Shen H Wang

Shen Wang

In a method of manufacturing a semiconductor device, a sacrificial gate structure including sacrificial gate electrode is formed over a substrate. A first dielectric layer is formed over the sacrificial gate structure. A second dielectric layer is formed over the first dielectric layer. The second and first dielectric layers are planarized and recessed, and an upper portion of the sacrificial gate structure is exposed. A third dielectric layer is formed over the exposed sacrificial gate structure and over the first dielectric layer. A fourth dielectric layer is formed over the third dielectric layer. The fourth and third dielectric layers are planarized, and the sacrificial gate electrode is exposed and part of the third dielectric layer remains on the recessed first dielectric layer. The recessing the first dielectric layer comprises a first etching operation and a second etching operation using a different etching as from the first etching operation.

Method of manufacturing a semiconductor device and a semiconductor device

Spacer layers on sidewalls of a dummy gate structure included in a semiconductor device are trimmed or etched prior to or during a replacement gate process in which the dummy gate structure is replaced with a replacement gate structure. A radical surface treatment operation is performed to etch the spacer layers, which is a type of plasma treatment in which radicals are generated using a plasma. The radicals in the plasma are used to etch the spacer layers such that the shape and/or the geometry of the remaining portions of the spacer layers reduces, minimizes, and/or prevents the likelihood of an antenna defect being formed in the spacer layers and/or in a work function metal layer of the replacement gate structure. This reduces, minimizes, and/or prevents the likelihood of occurrence of damage and/or defects in the replacement gate structure in subsequent processing operations for the semiconductor device.

Semiconductor device and methods of formation

A method, for making a semiconductor device, includes forming a first fin over a substrate. The method includes forming a dummy gate stack on the first fin. The method includes forming a first gate spacer along a side of the dummy gate stack. The first gate spacer includes a first dielectric material. The method includes forming a second gate spacer along a side of the first gate spacer. The second gate spacer includes a semiconductor material. The method includes forming a source/drain region in the first fin adjacent the second gate spacer. The method includes removing at least a portion of the second gate spacer to form a void extending between the first gate spacer and the source/drain region.

Fin field-effect transistor with void and method of forming the same

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Hsinchu, Taiwan

Hong Pin Lin