Advanced Micro Devices Corporation

Globalfoundries Inc.

International Business Machines Corporation

Kabushiki Kaisha Toshiba

Witold P Maszara

Srinath Krishnan

Ajey Poovannummoottil Jacob

Qi Xiang

Zoran Krivokapic

Ming-Ren Lin

Jody Alan Fronheiser

William George En

Mario M Pelella

Matthew S Buynoski

Kerem Akarvardar

Hemant Adhikari

Kangguo Cheng

Ruilong Xie

Ali Khakifirooz

Xiuyu Cai

Haihong Wang

Eric N Paton

Shekhar Pramanick

James N Pan

Nicholas V Licausi

Jung-Suk Goo

Niraj Subba

Bin Yu

Andy C Wei

Murat Kerem Akarvardar

David Paul Brunco

Robert J Miller

Jin Haeng Cho

Ming-Yin Hao

David S Bang

Hirohisa Kawasaki

Ihsan Djomehri

Zoran Krivakapic

Basker Veeraraghavan

Srinath Krisnan

Mario P Pelella

One illustrative device disclosed herein includes a substrate fin formed in a substrate comprised of a first semiconductor material, wherein at least a sidewall of the substrate fin is positioned substantially in a &#x3c;100&#x3e; crystallographic direction of the crystalline structure of the substrate, a replacement fin structure positioned above the substrate fin, wherein the replacement fin structure is comprised of a semiconductor material that is different from the first semiconductor material, and a gate structure positioned around at least a portion of the replacement fin structure.

Methods of forming low defect replacement fins for a FinFET semiconductor device and the resulting devices

One illustrative method disclosed herein involves forming a first fin for a first FinFET device in and above a semiconducting substrate, wherein the first fin is comprised of a first semiconductor material that is different from the material of the semiconducting substrate and, after forming the first fin, forming a second fin for a second FinFET device that is formed in and above the semiconducting substrate, wherein the second fin is comprised of a second semiconductor material that is different from the material of the semiconducting substrate and different from the first semiconductor material.

Methods of forming different FinFET devices with different threshold voltages and integrated circuit products containing such devices

One method of forming epi semiconductor cladding materials in the channel region of a semiconductor device is disclosed which includes forming a sacrificial gate structure around a portion of an initial fin, forming a sidewall spacer adjacent opposite sides of the sacrificial gate structure and removing the sacrificial gate structure so as to thereby define a replacement gate cavity, performing an etching process through the replacement gate cavity to remove portions of the initial fin so as to thereby define a reduced size fin and recesses under the sidewall spacers, forming at least one replacement epi semiconductor cladding material around the reduced size fin in the replacement gate cavity and in the recesses under the sidewall spacers, and forming a replacement gate structure within the replacement gate cavity around the at least one replacement epi semiconductor cladding material.

Channel cladding last process flow for forming a channel region on a FinFET device having a reduced size fin in the channel region

A method for forming a semiconductor device is provided including processing a wafer having a spacer layer and a structure layer, the spacer layer is over the structure layer. The method continues including forming a first sidewall spacer from the spacer layer, forming a structure strip from the structure layer below the first sidewall spacer, forming a masking structure over and intersecting the structure strip, and forming a vertical post from the structure strip below the masking structure.

Semiconductor device having structure with fractional dimension of the minimum dimension of a lithography system

One method disclosed includes, among other things, covering the top surface and a portion of the sidewalls of an initial fin structure with etch stop material, forming a sacrificial gate structure around the initial fin structure, forming a sidewall spacer adjacent the sacrificial gate structure, removing the sacrificial gate structure, with the etch stop material in position, to thereby define a replacement gate cavity, performing at least one etching process through the replacement gate cavity to remove a portion of the semiconductor substrate material of the fin structure positioned under the replacement gate cavity that is not covered by the etch stop material so as to thereby define a final fin structure and a channel cavity positioned below the final fin structure and substantially filling the channel cavity with a stressed material.

Methods of forming stressed channel regions for a FinFET semiconductor device and the resulting device

One method of forming epi semiconductor cladding materials in the channel region of a semiconductor device is disclosed which includes forming an initial epi semiconductor cladding material around the exposed portion of a fin for an entire axial length of the fin, forming a sacrificial gate structure around a portion of the fin and the initial cladding material, removing the sacrificial gate structure so as to thereby define a replacement gate cavity, performing an etching process through the replacement gate cavity to remove at least the exposed portion of the initial cladding material and thereby expose a surface of the fin within the replacement gate cavity, forming at least one replacement epi semiconductor cladding material around the exposed surface of the fin, and forming a replacement gate structure within the replacement gate cavity around the at least one replacement epi semiconductor cladding material.

Channel cladding last process flow for forming a channel region on a FinFET device

An illustrative method includes forming a FinFET device above structure comprising a semiconductor substrate, a first epi semiconductor material and a second epi semiconductor material that includes forming an initial fin structure that comprises portions of the semiconductor substrate, the first epi material and the second epi material, recessing a layer of insulating material such that a portion, but not all, of the second epi material portion of the initial fin structure is exposed so as to define a final fin structure, forming a gate structure above and around the final fin structure, removing the first epi material of the initial fin structure and thereby define an under-fin cavity under the final fin structure and substantially filling the under-fin cavity with a stressed material.

Various methods are disclosed herein for forming alternative fin materials that are in a stable or metastable condition. In one case, a stable replacement fin is grown to a height that is greater than an unconfined stable critical thickness of the replacement fin material and it has a defect density of 10defects/cmor less throughout its entire height. In another case, a metastable replacement fin is grown to a height that is greater than an unconfined metastable critical thickness of the replacement fin material and it has a defect density of 10defects/cmor less throughout at least 90% of its entire height.

Methods of forming replacement fins for a FinFET semiconductor device by performing a replacement growth process

One method disclosed includes, among other things, forming an initial fin structure comprised of portions of a substrate, a first epi semiconductor material and a second epi semiconductor material, forming a layer of insulating material so as to over-fill the trenches that define the fin, recessing a layer of insulating material such that a portion, but not all, of the second epi semiconductor portion of the final fin structure is exposed, forming a gate structure around the final fin structure, further recessing the layer of insulating material such that the first epi semiconductor material is exposed, removing the first epi semiconductor material to thereby define an under-fin cavity and substantially filling the under-fin cavity with a stressed material.

Methods of making fins and semiconductor structures containing fins are provided. The methods involve forming a multi-layer structure over a semiconductor substrate. The multi-layer structure comprises a first layer over the semiconductor substrate, a second layer over the first layer, and a third layer over the second layer. The method also comprises removing upper portions of the semiconductor substrate and portions of the multi-layer structure to form fins of the semiconductor substrate and portions of the multi-layer structure. Further, the method comprises selectively oxidizing the first layer while oxidization of the second layer and the third layer is less than the oxidization of the first layer. The oxidation can be performed before gap fill recess or after gap fill recess.

Methods of making fins and fin field effect transistors (FinFETs)

Fabrication methods for semiconductor device structures are provided. In an exemplary embodiment, a method of fabricating an electrically-isolated FinFET semiconductor device includes the steps of forming a silicon oxide layer over a semiconductor substrate including a silicon material and forming a first hard mask layer over the silicon oxide layer. The method further includes the steps of forming a first plurality of void spaces in the first hard mask layer and forming a second hard mask layer in the first plurality of void spaces. Still further, the method includes the steps of removing the remaining portions of the first hard mask layer, thereby forming a second plurality of void spaces in the second hard mask layer, extending the second plurality of void spaces into the silicon oxide layer, and forming a plurality of fin structures in the extended second plurality of void spaces.

Methods for fabricating electrically-isolated finFET semiconductor devices

Methods are provided for fabricating a semiconductor device. A method comprises forming a layer of a first semiconductor material overlying the bulk substrate and forming a layer of a second semiconductor material overlying the layer of the first semiconductor material. The method further comprises creating a fin pattern mask on the layer of the second semiconductor material and anisotropically etching the layer of the second semiconductor material and the layer of the first semiconductor material using the fin pattern mask as an etch mask. The anisotropic etching results in a fin formed from the second semiconductor material and an exposed region of first semiconductor material underlying the fin. The method further comprises forming an isolation layer in the exposed region of first semiconductor material underlying the fin.

Methods for forming isolated fin structures on bulk semiconductor material

One method involves providing a substrate comprised of first and second semiconductor materials, performing an etching process through a hard mask layer to define a plurality of trenches that define first and second portions of a fin for a FinFET device, wherein the first portion is the first material and the second portion is the second material, forming a layer of insulating material in the trenches, performing a planarization process on the insulating material, performing etching processes to remove the hard mask layer and reduce a thickness of the second portion, thereby defining a cavity, performing a deposition process to form a third portion of the fin on the second portion, wherein the third portion is a third semiconducting material that is different from the second material, and performing a process such that a post-etch upper surface of the insulating material is below an upper surface of the third portion.

Methods of forming FinFET devices with alternative channel materials

One illustrative method disclosed herein involves performing a first etching process through a patterned hard mask layer to define a plurality of spaced-apart trenches in a substrate that defines a first portion of a fin for the device, forming a layer of insulating material in the trenches and performing a planarization process on the layer of insulating material to expose the patterned hard, performing a second etching process to remove the hard mask layer and to define a cavity within the layer of insulating material, forming a second portion of the fin within the cavity, wherein the second portion of the fin is comprised of a semiconducting material that is different than the substrate, and performing a third etching process on the layer of insulating material such that an upper surface of the insulating material is below an upper surface of the second portion of the fin.

A semiconductor substrate is provided having an insulator thereon with a semiconductor layer on the insulator. A deep trench isolation is formed, introducing strain to the semiconductor layer. A gate dielectric and a gate are formed on the semiconductor layer. A spacer is formed around the gate, and the semiconductor layer and the insulator are removed outside the spacer. Recessed source/drain are formed outside the spacer.

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Morgan Hill, CA, United States of America

Witold P Maszara