Abstract: A semiconductor device including at least one self-aligned contact has at least one gate electrode on a bulk substrate layer of the semiconductor device. A gate cap encapsulates the at least one gate electrode. The semiconductor device further includes at least one contact separated from the at least one gate electrode via a portion of the gate cap. The at least one contact includes a metal portion that directly contacts the gate cap.

Abstract: A semiconductor structure may be formed by forming a fin on a substrate, forming a gate over a portion of the fin, removing a portion of the fin not below the gate to expose a sidewall of the fin beneath the gate and a top surface of the substrate, forming a first protective layer on the top surface of the substrate but not on the sidewall of the fin, forming a second protective layer on the sidewall of the fin prevented from forming on the top surface of the substrate by the first protective layer, removing the first protective layer to expose the top surface of the substrate, forming a buffer layer on the top surface of the substrate; the buffer layer prevented from forming on the sidewall of the fin by the second protective layer, and forming a source-drain region on the buffer layer electrically connected to the fin.

Abstract: A semiconductor structure may be formed by forming a fin on a substrate, forming a gate over a portion of the fin, removing a portion of the fin not below the gate to expose a sidewall of the fin beneath the gate and a top surface of the substrate, forming a first protective layer on the top surface of the substrate but not on the sidewall of the fin, forming a second protective layer on the sidewall of the fin prevented from forming on the top surface of the substrate by the first protective layer, removing the first protective layer to expose the top surface of the substrate, forming a buffer layer on the top surface of the substrate; the buffer layer prevented from forming on the sidewall of the fin by the second protective layer, and forming a source-drain region on the buffer layer electrically connected to the fin.

Abstract: A semiconductor structure may be formed by forming a sacrificial gate above a substrate covered by a hard mask, depositing a first interlevel dielectric (ILD) layer above the sacrificial gate, recessing the first ILD layer to a thickness less than the height of the sacrificial gate, depositing an etch barrier layer above the first ILD layer, depositing a second ILD layer above the etch barrier layer, planarizing the second ILD layer and the etch barrier layer to expose the hard mask using the hard mask as a planarization stop, removing the hard mask and sacrificial gate to form a gate cavity, forming a replacement metal gate in the gate cavity, removing the second ILD layer, and planarizing the replacement metal gate using the etch barrier layer as a planarization stop. A supplementary electrode layer may be formed above the replacement metal gate prior to planarizing the replacement metal gate.

Abstract: A method of forming transistors is provided. The method includes forming a plurality of transistor structures to have a plurality of dummy gates on a substrate. Each dummy gate is surrounded by sidewall spacers of a height, which is less than the dummy gate and is different for different transistor structures resulting in divots of different depths above the sidewall spacers. The method then deposits a conformal dielectric layer on top of the dummy gates and inside the divots of the plurality of transistor structures with the conformal dielectric layer having a thickness of at least half of a width of the divots, removes only a portion of the conformal dielectric layer that is on top of the dummy gates to expose the dummy gates; and replaces the dummy gates with a plurality of high-k metal gates.

Abstract: A semiconductor structure may be formed by forming a sacrificial gate above a substrate covered by a hard mask, depositing a first interlevel dielectric (ILD) layer above the sacrificial gate, recessing the first ILD layer to a thickness less than the height of the sacrificial gate, depositing an etch barrier layer above the first ILD layer, depositing a second ILD layer above the etch barrier layer, planarizing the second ILD layer and the etch barrier layer to expose the hard mask using the hard mask as a planarization stop, removing the hard mask and sacrificial gate to form a gate cavity, forming a replacement metal gate in the gate cavity, removing the second ILD layer, and planarizing the replacement metal gate using the etch barrier layer as a planarization stop. A supplementary electrode layer may be formed above the replacement metal gate prior to planarizing the replacement metal gate.

Abstract: Embodiments of the invention include methods of forming borderless contacts for semiconductor transistors. Embodiments may include providing a transistor structure including a gate, a spacer on a sidewall of the gate, a hard cap above the gate, a source/drain region adjacent to the spacer, and an interlevel dielectric layer around the gate, forming a contact hole above the source/drain region, forming a protective layer on portions of the hard cap and of the spacer exposed by the contact hole; deepening the contact hole by etching the interlevel dielectric layer while the spacer and the hard cap are protected by the protective layer, so that at least a portion of the source/drain region is exposed by the deepening of the contact hole; removing the protective layer; and forming a metal contact in the contact hole.