International Business Machines Corporation

Globalfoundries Inc.

Sameer Hemchand Jain

Reinaldo Ariel Vega

Emre Alptekin

Viraj Yashawant Sardesai

Cung D Tran

Ramachandra Divakaruni

Keith Howard Tabakman

Ravikumar Ramachandran

Henry K Utomo

Alexander Reznicek

Carl John Radens

Oleg Gluschenkov

Dominic Joseph Schepis

Jeffrey Bowman Johnson

Richard Stephan Wise

Shreesh Narasimha

Zhengwen O Li

Brian Joseph Greene

Unoh Kwon

Viorel C Ontalus

William K Henson

Shahab Siddiqui

Karen A Nummy

Jay William Strane

Ying Li

Hari V Mallela

Yaocheng Liu

Yue Ke

Melissa Alyson Smith

Hasan Munir Nayfeh

Jang Sim

Benjamin G Moser

Ayse M Ozbek

A third type of metal gate stack is provided above an isolation structure and between a replacement metal gate n-type field effect transistor and a replacement metal gate p-type field effect transistor. The third type of metal gate stack includes at least three different components. Notably, the third type of metal gate stack includes, as a first component, an n-type workfunction metal layer, as a second component, a p-type workfunction metal layer, and as a third component, a low resistance metal layer. In some embodiments, the uppermost surface of the first, second and third components of the third type of metal gate stack are all substantially coplanar with each other. In other embodiments, an uppermost surface of the third component of the third type of metal gate stack is non-substantially coplanar with an uppermost surface of both the first and second components of the third type of metal gate stack.

Third type of metal gate stack for CMOS devices

Methods of fabricating integrated circuit devices for forming uniform and well controlled fin recesses are disclosed. One method includes, for instance: obtaining an intermediate semiconductor structure having a substrate, at least one fin disposed on the substrate, at least one gate structure positioned over the at least one fin, and at least one oxide layer disposed on the substrate and about the at least one fin and the at least one gate structure; implanting germanium (Ge) in a first region of the at least one fin; and removing the first region of the at least one fin implanted with Ge.

Methods of forming uniform and pitch independent fin recess

After formation of gate structures over semiconductor fins and prior to formation of raised active regions, a directional ion beam is employed to form a dielectric material portion on end walls of semiconductor fins that are perpendicular to the lengthwise direction of the semiconductor fins. The angle of the directional ion beam is selected to be with a vertical plane including the lengthwise direction of the semiconductor fins, thereby avoiding formation of the dielectric material portion on lengthwise sidewalls of the semiconductor fins. Selective epitaxy of semiconductor material is performed to grow raised active regions from sidewall surfaces of the semiconductor fins. Optionally, horizontal portions of the dielectric material portion may be removed prior to the selective epitaxy process. Further, the dielectric material portion may optionally be removed after the selective epitaxy process.

Fin end spacer for preventing merger of raised active regions

A semiconductor device includes a trench region in an interconnect level dielectric layer. A silicide layer is on the bottom of the trench region. Opposing minor sides of the trench region include a spacer layer, but the central portion of the trench region is substantially free from the spacer layer. The spacer layer is formed using an angled gas cluster ion beam.

Unidirectional spacer in trench silicide

Angled directional ion beams are directed to sidewalls of a gate structure that straddles at least one semiconductor fin. The directions of the angled directional ion beams are contained within a vertical plane that is parallel to the sidewalls of the at least one semiconductor. A pair of gate spacers are formed on sidewalls of the gate structure by accumulation of the deposited dielectric material from the angled directional ion beams and without use of an anisotropic etch, while the sidewalls of the semiconductor fins parallel to the directional ion beams remain physically exposed. A selective epitaxy process can be performed to form raised active regions by growing a semiconductor material from the sidewalls of the semiconductor fins.

Selective dielectric spacer deposition for exposing sidewalls of a finFET

A plurality of sacrificial gate structures is formed on substrate. A first set of sacrificial gate structures of the plurality of sacrificial gate structures contains a sacrificial spacer on sidewall surfaces thereof, and a second set of sacrificial gate structures of the plurality of sacrificial gate structures has bare sidewall surfaces. A dielectric spacer is provided to the first and second sets of sacrificial gate structures. Each sacrificial gate structure of the first and second sets is removed together with the sacrificial spacers providing first gate cavities in the area previously occupied by a sacrificial gate structure of the first set of sacrificial gate structures and the sacrificial spacer and second gate cavities in the area previously occupied by a sacrificial gate structure of the second set of sacrificial gate structures. A functional gate is formed in each of the first and second gate cavities.

Formation of functional gate structures with different critical dimensions using a replacement gate process

An aspect of the invention includes a method for forming a semiconductor device with a two-step silicide formation. First, a silicide intermix layer is formed over a source/drain region and a portion of an adjacent extension region. Any spacers removed to accomplish this may be replaced. Dielectric material covers the silicide intermix layer over the source/drain region. A contact opening for a via is etched into the dielectric material. A second silicide contact is formed on the silicide intermix layer, or may be formed within the source/drain region as long as the second silicide contact still contacts the silicide intermix layer.

Two-step silicide formation

One embodiment of the present invention comprises a transistor having a source/drain region within a substrate, an extension region within the substrate adjoining the source/drain region and extending toward a gate on the substrate, and a dielectric spacer against the gate wherein the dielectric spacer covers at least part of the extension region. A silicide intermix layer is formed over both the source/drain region and a portion of the extension region. A silicide contact is formed through the silicide intermix layer over the source/drain region.

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Beacon, NY, United States of America

Sameer Hemchand Jain