Abstract: Disclosed herein is a method of forming self-aligned contacts for a semiconductor device. In one example, the method includes forming a plurality of spaced-apart sacrificial gate electrodes above a semiconducting substrate, wherein each of the gate electrodes has a gate cap layer positioned on the gate electrode, and performing at least one etching process to define a self-aligned contact opening between the plurality of spaced-apart sacrificial gate electrodes. The method further includes removing the gate cap layers to thereby expose an upper surface of each of the sacrificial gate electrodes, depositing at least one layer of conductive material in said self-aligned contact opening and removing portions of the at least one layer of conductive material that are positioned outside of the self-aligned contact opening to thereby define at least a portion of a self-aligned contact positioned in the self-aligned contact opening.

Abstract: When forming sophisticated multiple gate transistors and planar transistors in a common manufacturing sequence, the threshold voltage characteristics of the multiple gate transistors may be intentionally “degraded” by selectively incorporating a dopant species into corner areas of the semiconductor fins, thereby obtaining a superior adaptation of the threshold voltage characteristics of multiple gate transistors and planar transistors. In advantageous embodiments, the incorporation of the dopant species may be accomplished by using the hard mask, which is also used for patterning the self-aligned semiconductor fins.

Abstract: A silicon/carbon alloy may be formed in drain and source regions, wherein another portion may be provided as an in situ doped material with a reduced offset with respect to the gate electrode material. For this purpose, in one illustrative embodiment, a cyclic epitaxial growth process including a plurality of growth/etch cycles may be used at low temperatures in an ultra-high vacuum ambient, thereby obtaining a substantially bottom to top fill behavior.

Abstract: Embodiments herein provide approaches for forming a diffusion break during a replacement metal gate process. Specifically, a semiconductor device is provided with a set of replacement metal gate (RMG) structures over a set of fins patterned from a substrate; a dielectric material over an epitaxial junction area; an opening formed between the set of RMG structures and through the set of fins, wherein the opening extends through the dielectric material, the expitaxial junction area, and into the substrate; and silicon nitride (SiN) deposited within the opening to form the diffusion break.

Abstract: 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.

Abstract: Methods are provided for fabricating an integrated circuit that includes gate to active contacts. One method includes forming a dummy gate structure including a dummy gate electrode having sidewalls and overlying a semiconductor substrate and first and second sidewall spacers on the sidewalls of the dummy gate electrode. The method includes removing the dummy gate electrode to form a trench bounded by the first and second sidewall spacers. The method removes an upper portion of the first sidewall spacer and deposits a layer of metal in the trench and over a remaining portion of the first sidewall spacer to form a gate electrode and an interconnect.

Abstract: Methods are provided for fabricating integrated circuits. One method includes etching a plurality of trenches into a silicon substrate and filling the trenches with an insulating material to delineate a plurality of spaced apart silicon fins. A layer of undoped silicon is epitaxially grown to form an upper, undoped region of the fins. Dummy gate structures are formed overlying and transverse to the plurality of fins and a back fill material fills between the dummy gate structures. The dummy gate structures are removed to expose a portion of the fins and a high-k dielectric material and a work function determining gate electrode material are deposited overlying the portion of the fins. The back fill material is removed to expose a second portion and metal silicide contacts are formed on the second portion. Conductive contacts are then formed to the work function determining material and to the metal silicide.

Abstract: In a semiconductor device comprising sophisticated high-k metal gate structures formed in accordance with a replacement gate approach, semiconductor-based resistors may be formed above isolation structures substantially without being influenced by the replacement gate approach. Consequently, enhanced area efficiency may be achieved compared to conventional strategies, in which the resistive structures may have to be provided on the basis of a gate electrode metal, while, nevertheless, a low parasitic capacitance may be accomplished due to providing the resistive structures above the isolation structure.

Abstract: 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.

Abstract: A method for fabricating a FinFET integrated circuit includes depositing a first polysilicon layer at a first end of a diffusion region and a second polysilicon layer at a second end of the diffusion region; diffusing an n-type material into the diffusion region to form a diffused resistor; and epitaxially growing a silicon material between the first and second polysilicon layers to form fins structures over the diffused resistor and spanning between the first and second polysilicon layers.

Abstract: Methods are provided for fabricating an integrated circuit that includes gate to active contacts. One method includes processing the IC in a replacement gate technology including forming dummy gates, sidewall spacers on the dummy gates, and metal silicide contacts to active areas. A fill layer is deposited and planarized to expose the dummy gates and the dummy gates are removed. A mask is formed having an opening overlying a portion of the channel region from which the dummy gate was removed and a portion of an adjacent metal silicide contact. The fill layer and a portion of the sidewall spacers exposed through the mask opening are etched to expose a portion of the adjacent metal silicide contact. A gate electrode material is deposited overlying the channel region and exposed metal silicide contact and is planarized to form a gate electrode and a gate-to-metal silicide contact interconnect.

Abstract: Non-planar transistors, such as FinFETs, may be formed in a bulk configuration in the context of a replacement gate approach, wherein the semiconductor fins are formed during the replacement gate sequence. To this end, in some illustrative embodiments, a buried etch mask may be formed in an early manufacturing stage on the basis of superior process conditions.

Abstract: When forming sophisticated high-k metal gate electrode structures on the basis of a replacement gate approach, the fill conditions upon filling in the highly conductive electrode metal, such as aluminum, may be enhanced by removing an upper portion of the final work function metal, for instance a titanium nitride material in P-channel transistors. In some illustrative embodiments, the selective removal of the metal-containing electrode material in an upper portion of the gate opening may be accomplished without unduly increasing overall process complexity.

Abstract: By forming an additional dielectric material, such as silicon nitride, after patterning dielectric liners of different intrinsic stress, a significant increase of performance of N-channel transistors may be obtained while substantially not contributing to a performance loss of the P-channel transistor.

Abstract: Three-dimensional transistors in a bulk configuration may be formed on the basis of gate openings or gate trenches provided in a mask material. Hence, self-aligned semiconductor fins may be efficiently patterned in the underlying active region in a portion defined by the gate opening, while other gate openings may be efficiently masked, in which planar transistors are to be provided. After patterning the semiconductor fins and adjusting the effective height thereof, the further processing may be continued on the basis of process techniques that may be commonly applied to the planar transistors and the three-dimensional transistors.

Abstract: 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.

Abstract: A non-conformal metal silicide in a transistor of recessed drain and source configuration may provide enhanced efficiency with respect to strain-inducing mechanisms, drain/source resistance and the like. For this purpose, in some cases, an amorphizing implantation process may be performed prior to the silicidation process, while in other cases an anisotropic deposition of the refractory metal may be used.

Abstract: 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.

Abstract: Generally, the subject matter disclosed herein relates to modern sophisticated semiconductor devices and methods for forming the same, wherein a reduced threshold voltage (Vt) may be achieved in HK/MG transistor elements that are manufactured based on replacement gate electrode integrations. One illustrative method disclosed herein includes forming a first metal gate electrode material layer above a gate dielectric material layer having a dielectric constant of approximately 10 or greater. The method further includes exposing the first metal gate electrode material layer to an oxygen diffusion process, forming a second metal gate electrode material layer above the first metal gate electrode material layer, and adjusting an oxygen concentration gradient and a nitrogen concentration gradient in at least the first metal gate electrode material layer and the gate dielectric material layer.

Abstract: When forming cavities in active regions of semiconductor devices in order to incorporate a strain\-inducing semiconductor material, superior uniformity may be achieved by using an implantation process so as to selectively modify the etch behavior of exposed portions of the active region. In this manner, the basic configuration of the cavities may be adjusted with a high degree of flexibility, while at the same time the dependence on pattern loading effect may be reduced. Consequently, a significantly reduced variability of transistor characteristics may be achieved.