Abstract: Methods of forming a SAC cap with SiN U-shaped and oxide T-shaped structures and the resulting devices are provided. Embodiments include forming a substrate with a trench and a plurality of gate structures; forming a nitride liner over portions of the substrate and along sidewalls of each gate structure; forming an ILD between each gate structure and in the trench; recessing each gate structure between the ILD; forming a U-shaped nitride liner over each recessed gate structure; forming an a-Si layer over the nitride liner and the U-shaped nitride liner; removing portions of the nitride liner, the U-shaped nitride liner and the a-Si layer; forming a W layer over portions of the substrate adjacent to and between the a-Si layer; forming an oxide liner over the nitride liner, the U-shaped nitride liner and along sidewalls of the W layer; and forming an oxide layer over portions of the oxide liner.

Abstract: The present disclosure relates to semiconductor structures and, more particularly, to a corrosion and/or etch protection layer for contacts and interconnect metallization integration structures and methods of manufacture. The structure includes a metallization structure formed within a trench of a substrate and a layer of cobalt phosphorous (CoP) on the metallization structure. The CoP layer is structured to prevent metal migration from the metallization structure and corrosion of the metallization structure during etching processes.

Abstract: The present disclosure relates to semiconductor structures and, more particularly, to a corrosion and/or etch protection layer for contacts and interconnect metallization integration structures and methods of manufacture. The structure includes a metallization structure formed within a trench of a substrate and a layer of cobalt phosphorous (CoP) on the metallization structure. The CoP layer is structured to prevent metal migration from the metallization structure and corrosion of the metallization structure during etching processes.

Abstract: The present disclosure generally relates to semiconductor structures and, more particularly, to gate structures with minimized gate thickness loss and methods of manufacture. The structure includes: a plurality of gate structures; a film layer provided over the gate structures and adjacent to the gate structures; and a planarized cap layer on the film and over the plurality of gate structures, the planarized cap layer having a different selectivity to slurry of a chemical mechanical polishing (CMP) process than the film.

Abstract: A method and apparatus are provided for automatically controlling the position of the spray bars and nozzles and the spray flow of a CMP in-situ cleaning module. Embodiments include fixing a wafer to a CMP cleaning module, the cleaning module having a first and a second group of spray bars and nozzles, the first and second groups of spray bars and nozzles being located proximate to opposite surfaces of the wafer; cleaning one or more of the surfaces of the wafer with a chemical spray forced through at least one of the groups of spray bars and nozzles; determining a measured profile of the one or more surfaces of the wafer; comparing the measured profile against a target profile; and adjusting automatically at least one of the first and second groups of spray bars and nozzles relative to the one or more surfaces of the wafer based on the comparison.

Abstract: Devices and methods of forming an integrated circuit and a FinFET device with a planarized permanent layer are provided. In an embodiment, a method of forming a planarized permanent layer includes providing a base substrate that has an uneven surface topography. A permanent layer is conformally formed over the base substrate. The permanent layer includes raised portions and sunken portions that correspond to the surface topography of the base substrate. A sacrificial layer is conformally formed over the permanent layer. The sacrificial layer and the raised portions of the permanent layer are chemical-mechanical planarized to provide the planarized permanent layer. The sacrificial layer is substantially completely removed after chemical-mechanical planarizing.

Abstract: Devices and methods of forming an integrated circuit and a FinFET device with a planarized permanent layer are provided. In an embodiment, a method of forming a planarized permanent layer includes providing a base substrate that has an uneven surface topography. A permanent layer is conformally formed over the base substrate. The permanent layer includes raised portions and sunken portions that correspond to the surface topography of the base substrate. A sacrificial layer is conformally formed over the permanent layer. The sacrificial layer and the raised portions of the permanent layer are chemical-mechanical planarized to provide the planarized permanent layer. The sacrificial layer is substantially completely removed after chemical-mechanical planarizing.

Abstract: A semiconductor structure includes a source region, a drain region, a channel region and a gate region over a bulk silicon substrate. The gate region further includes a dielectric layer and one or more work function layers disposed over the dielectric layer. A first filler material, such as a flowable oxide is provided over the source region and the drain region. A second filler material, such as an organic material, is provided within the gate region. The first filler material and the second filler material are selectively removed to create, source, drain and gate openings. The gate, source and drain openings are filled simultaneously with a metal, such as tungsten, to create a metal gate structure, source contact and drain contact.

Abstract: Embodiments of the present invention provide improved methods for fabrication of finFETs. During finFET fabrication, a film, such as amorphous silicon, is deposited on a semiconductor substrate which has regions with fins and regions without fins. A fill layer is deposited on the film and planarized to form a flush surface. A recess or etch process is used to form a planar surface with all portions of the fill layer removed. A finishing process such as a gas cluster ion beam process may be used to further smooth the substrate surface. This results in a film having a very uniform thickness across the structure (e.g. a semiconductor wafer), resulting in improved within-wafer (WiW) uniformity and improved within-chip (WiC) uniformity.

Abstract: A semiconductor structure includes a source region, a drain region, a channel region and a gate region over a bulk silicon substrate. The gate region further includes a dielectric layer and one or more work function layers disposed over the dielectric layer. A first filler material, such as a flowable oxide is provided over the source region and the drain region. A second filler material, such as an organic material, is provided within the gate region. The first filler material and the second filler material are selectively removed to create, source, drain and gate openings. The gate, source and drain openings are filled simultaneously with a metal, such as tungsten, to create a metal gate structure, source contact and drain contact.