International Business Machines Corporation

Globalfoundries Inc.

Huihang Dong

Wai-Kin Li

Ruqiang Bao

John Anthony Fitzsimmons

Unoh Kwon

Kuang-Jung Chen

Scott D Allen

A patterning scheme to minimize dry/wet strip induced device degradation and resultant devices are provided. The method includes removing a workfunction material over a first device area of a structure, while protecting the workfunction material over a second device area of the structure with a first masking material. The method further includes applying a second masking material over the first device area and the first masking material. The method further includes removing the first masking material and the second masking material until the workfunction material is exposed over the second device area.

Patterning scheme to minimize dry/wets strip induced device degradation

An IC structure including: a first replacement gate stack for the pFET, the first replacement gate stack including: an interfacial layer in a first opening in the dielectric layer; a high-k layer over the interfacial layer in the first opening; a pFET work function metal layer over the high-k layer in the first opening; and a first gate electrode layer over the pFET work function metal layer and substantially filling the first opening; and a second replacement gate stack for the nFET, the second gate stack laterally adjacent to the first gate stack and including: the interfacial layer in a second opening in the dielectric layer; the high-k layer over the interfacial layer in the second opening; a nFET work function metal layer over the high-k layer in the second opening; and a second gate electrode layer over the nFET work function metal layer and substantially filling the second opening.

Integrated circuit with replacement gate stacks and method of forming same

After forming an organic planarization layer (OPL) atop a substrate which includes a plurality of semiconductor fins and a gate structure thereon, the OPL is recessed such that uppermost surfaces of remaining portions of the OPL are located below an uppermost surface of the gate structure but above top surfaces of the semiconductor fins. The remaining portions of the OPL are patterned to expose semiconductor fins in a pFinFET region for subsequent ion implantation. Portions of the OPL that remain on the semiconductor fins in an nFinFET region act as an implantation mask to shield the semiconductor fins in the nFinFET region from the ion implantation.

Patterning process for Fin implantation

Patterning process for fin implantation

Embodiments of the present disclosure provide a method of processing an integrated circuit (IC) structure for metal gate replacement, the method comprising: providing a structure including a first semiconductor fin and a second semiconductor fin positioned over a buried insulator layer of a silicon-on-insulator (SOI) substrate, and a gate structure positioned over the first and second semiconductor fins, wherein the gate structure includes a gate dielectric layer and a metal layer positioned over the gate dielectric layer; forming a planarizing resist over the first and second semiconductor fins, wherein the planarizing resist includes: a first organic planarizing layer (OPL), and a second OPL over the first OPL; removing a portion of the second OPL; removing an exposed portion of the first OPL and a portion of the metal layer positioned over the second semiconductor fin; and forming a replacement metal gate (RMG) over the gate dielectric layer.

Processing of integrated circuit for metal gate replacement

A stack of a dielectric material layer and a metallic material layer are formed on a substrate. A first organic planarization layer, a non-metallic hard mask layer, and a photoresist layer are sequentially deposited over the metallic material layer. The photoresist layer is lithographically patterned, and the pattern in the photoresist layer is transferred through the non-metallic hard mask layer, the first organic planarization layer, and the metallic material layer to form a cavity. A second organic planarization layer is deposited within the cavity and over remaining portions of the photoresist layer. The second organic planarization layer and the photoresist layer are recessed, and the non-metallic hard mask layer is subsequently removed. Remaining portions of the first and second organic planarization layers are simultaneously removed to provide physically exposed surfaces of the patterned metallic material layer and a top surface of the dielectric material layer.

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Ridgefield, CT, United States of America

Huihang Dong