Forming merged lines in a metallization layer by replacing sacrificial lines with conductive lines

Abstract

A method includes forming a plurality of sacrificial lines embedded in a first dielectric layer. A line merge opening and a line cut opening are formed in a hard mask layer formed above the first dielectric layer. Portions of the first dielectric layer exposed by the line merge opening are removed to define a line merge recess. A portion of a selected sacrificial line exposed by the line cut opening is removed to define a line cut recess between first and second segments of the selected sacrificial line. A second dielectric layer is formed in the line cut recess. The hard mask is removed. The plurality of sacrificial lines is replaced with a conductive material to define at least one line having third and fourth segments in locations previously occupied by the first and second segments and to define a line-merging conductive structure in the line merge recess.