Globalfoundries Inc.

Nantero, Inc.

Richard Carter

Sven Beyer

Martin Trentzsch

Peter Baars

Stephan Kronholz

Thomas Rueckes

Andy C Wei

Rohit Pal

Berthold Reimer

Robert Binder

Claude Louis Bertin

Shiqun Gu

Peter Austin Burke

Markus Lenski

Verne C Hornback

Carsten Grass

Peter McGrath

Joachim Metzger

Boris Bayha

Fernando Koch

Gisela Schammler

James Elmer

Till Schloesser

Thilo Scheiper

Rolf Stephan

Matthias Schaller

Frank Jakubowski

Klaus Hempel

Elke Erben

Falk Graetsch

Joanna Wasyluk

Frank Ludwig

Torben Kelwing

Yew-Tuck Chow

Kai Tern Sih

Berthold Reimes

A semiconductor device includes a plurality of NMOS transistor elements, each including a first gate electrode structure above a first active region, at least two of the plurality of first gate electrode structures including a first encapsulating stack having a first dielectric cap layer and a first sidewall spacer stack. The semiconductor device also includes a plurality of PMOS transistor elements, each including a second gate electrode structure above a second active region, wherein at least two of the plurality of second gate electrode structures include a second encapsulating stack having a second dielectric cap layer and a second sidewall spacer stack. Additionally, the first and second sidewall spacer stacks each include at least three dielectric material layers, wherein each of the three dielectric material layers of the first and second sidewall spacer stacks include the same dielectric material.

Encapsulation of closely spaced gate electrode structures

Disclosed herein are various embodiments of an improved metal gate structure for semiconductor devices, such as transistors. In one example disclosed herein, a transistor has a gate structure consisting of a gate insulation layer positioned on a semiconducting substrate, a high-k insulation layer positioned on the gate insulation layer, a layer of titanium nitride positioned on the high-k insulation layer, a layer of aluminum positioned on the layer of titanium nitride and a layer of polysilicon positioned on the layer of aluminum.

Metal gate structure for semiconductor devices

When forming self-aligned contact elements in sophisticated semiconductor devices in which high-k metal gate electrode structures are to be provided on the basis of a replacement gate approach, the self-aligned contact openings are filled with an appropriate fill material, such as polysilicon, while the gate electrode structures are provided on the basis of a placeholder material that can be removed with high selectivity with respect to the sacrificial fill material. In this manner, the high-k metal gate electrode structures may be completed prior to actually filling the contact openings with an appropriate contact material after the removal of the sacrificial fill material. In one illustrative embodiment, the placeholder material of the gate electrode structures is provided in the form of a silicon/germanium material.

Semiconductor device comprising replacement gate electrode structures and self-aligned contact elements formed by a late contact fill

When forming sophisticated semiconductor devices, a replacement gate approach may be applied in combination with a self-aligned contact regime by forming the self-aligned contacts prior to replacing the placeholder material of the gate electrode structures.

Semiconductor device comprising self-aligned contact elements

Disclosed herein are various methods of forming replacement gate structures and conductive contacts on semiconductor devices and devices incorporating the same. One exemplary device includes a plurality of gate structures positioned above a semiconducting substrate, at least one sidewall spacer positioned proximate respective sidewalls of the gate structures, and a metal silicide region in a source/drain region of the semiconducting substrate, the metal silicide region extending laterally so as to contact the sidewall spacer positioned proximate each of the gate structures. Furthermore, the device also includes, among other things, a conductive contact positioned between the plurality of gate structures, the conductive contact having a lower portion that conductively contacts the metal silicide region and an upper portion positioned above the lower portion, wherein the lower portion is laterally wider than the upper portion and extends laterally so as to contact the sidewall spacers positioned proximate each of the gate structures.

Semiconductor devices with replacement gate structures having conductive contacts positioned therebetween

When forming high-k metal gate electrode structures by providing the gate dielectric material in an early manufacturing stage, the heat treatment or anneal process may be applied after incorporating work function metal species and prior to capping the gate dielectric material with a metal-containing electrode material. In this manner, the CET for a given physical thickness for the gate dielectric layer may be significantly reduced.

CET and gate current leakage reduction in high-k metal gate electrode structures by heat treatment after diffusion layer removal

When forming high-k metal gate electrode structures in transistors of different conductivity type while also incorporating an embedded strain-inducing semiconductor alloy selectively in one type of transistor, superior process uniformity may be accomplished by selectively reducing the thickness of a dielectric cap material of a gate layer stack above the active region of transistors which do not receive the strain-inducing semiconductor alloy. In this case, superior confinement and thus integrity of sensitive gate materials may be accomplished in process strategies in which the sophisticated high-k metal gate electrode structures are formed in an early manufacturing stage, while, in a replacement gate approach, superior process uniformity is achieved upon exposing the surface of a placeholder electrode material.

High-K metal gate electrode structures formed by early cap layer adaptation

A method for fabricating an integrated circuit is disclosed that includes, in accordance with an embodiment, providing an integrated circuit comprising a p-type field effect transistor (pFET), recessing a surface region of the pFET using an ammonia-hydrogen peroxide-water (APM) solution to form a recessed pFET surface region, and depositing a silicon-based material channel on the recessed pFET surface region.

Methods for pFET fabrication using APM solutions

Generally, the present disclosure is directed to techniques for improving the reliability of semiconductor devices with high-k gate dielectric layers by passivating point defects during the gate stack formation. One illustrative method disclosed herein includes performing a plurality of material deposition cycles to form a high-k dielectric layer above a semiconductor material layer, and introducing a passivating material into a gaseous precursor that is used for forming the high-k dielectric layer during at least one of the plurality of material deposition cycles.

Passivating point defects in high-K gate dielectric layers during gate stack formation

When forming sophisticated semiconductor devices, three-dimensional transistors in combination with planar transistors may be formed on the basis of a replacement gate approach and self-aligned contact elements by forming the semiconductor fins in an early manufacturing stage, i.e., upon forming shallow trench isolations, wherein the final electrically effective height of the semiconductor fins may be adjusted after the provision of self-aligned contact elements and during the replacement gate approach.

Fin-transistor formed on a patterned STI region by late fin etch

The work function of a high-k gate electrode structure may be adjusted in a late manufacturing stage on the basis of a lanthanum species in an N-channel transistor, thereby obtaining the desired high work function in combination with a typical conductive barrier material, such as titanium nitride. For this purpose, in some illustrative embodiments, the lanthanum species may be formed directly on the previously provided metal-containing electrode material, while an efficient barrier material may be provided in the P-channel transistor, thereby avoiding undue interaction of the lanthanum species in the P-channel transistor.

Work function adjustment in a high-K gate electrode structure after transistor fabrication by using lanthanum

Generally, the subject matter disclosed herein relates to sophisticated semiconductor devices and methods for forming the same, wherein the pitch between adjacent gate electrodes is aggressively scaled, and wherein self-aligning contact elements may be utilized to avoid the high electrical resistance levels commonly associated with narrow contact elements formed using typically available photolithography techniques. One illustrative embodiment includes forming first and second gate electrode structures above a semiconductor substrate, then forming a first layer of a first dielectric material adjacent to or in contact with the sidewalls of each of the first and second gate electrode structures. The illustrative method further includes a step of forming a second layer of a second dielectric material on the first layer, followed by forming a third layer of a third dielectric material on the second layer, wherein forming the third layer further comprises forming a first horizontal portion of the third layer above a surface of the semiconductor substrate between the first and second gate electrode structures.

Sophisticated gate electrode structures may be formed by providing a cap layer including a desired species that may diffuse into the gate dielectric material prior to performing a treatment for stabilizing the sensitive gate dielectric material. In this manner, complex high-k metal gate electrode structures may be formed on the basis of reduced temperatures and doses for a threshold adjusting species compared to conventional strategies. Moreover, a single metal-containing electrode material may be deposited for both types of transistors.

Adjusting threshold voltage for sophisticated transistors by diffusing a gate dielectric cap layer material prior to gate dielectric stabilization

In sophisticated approaches for forming high-k metal gate electrode structures in an early manufacturing stage, a threshold adjusting semiconductor alloy may be deposited on the basis of a selective epitaxial growth process without affecting the back side of the substrates. Consequently, any negative effects, such as contamination of substrates and process tools, reduced surface quality of the back side and the like, may be suppressed or reduced by providing a mask material and preserving the material at least during the selective epitaxial growth process.

Reducing contamination in a process flow of forming a channel semiconductor alloy in a semiconductor device

When forming sophisticated gate electrode structures of transistor elements of different type, the threshold adjusting channel semiconductor alloy may be provided prior to forming isolation structures, thereby achieving superior uniformity of the threshold adjusting material. Consequently, threshold variability on a local and global scale of P-channel transistors may be significantly reduced.

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Dresden, Germany

Richard Carter