Abstract: A methodology for forming a fin field effect transistor (FinFET) includes the co-integration of various isolation structures, including gate cut and shallow diffusion break isolation structures that are formed with common masking and etching steps. Following an additional patterning step to provide segmentation for source/drain conductive contacts, a single deposition step is used to form an isolation dielectric layer within each of gate cut openings, shallow diffusion break openings and cavities over shallow trench isolation between device active areas.

Abstract: One illustrative method disclosed herein includes forming a low-k sidewall spacer adjacent opposing sidewalls of a gate structure, forming contact etch stop layers (CESLs) adjacent the low-k sidewall spacer in the source/drain regions of the transistor, and forming a first insulating material above the CESLs. In this example, the method also includes recessing the first insulating material so as to expose substantially vertically oriented portions of the CESLs, removing a portion of a lateral width of the substantially vertically oriented portions of the CESLs so as to form trimmed CESLs, and forming a high-k spacer on opposite sides of the gate structure, wherein at least a portion of the high-k spacer is positioned laterally adjacent the trimmed substantially vertically oriented portions of the trimmed CESLs.

Abstract: Parallel fins are formed (in a first orientation), and source/drain structures are formed in or on the fins, where channel regions of the fins are between the source/drain structures. Parallel gate structures are formed to intersect the fins (in a second orientation perpendicular to the first orientation), source/drain contacts are formed on source/drain structures that are on opposite sides of the gate structures, and caps are formed on the source/drain contacts. After forming the caps, a gate cut structure is formed interrupting the portion of the gate structure that extends between adjacent fins. The upper portion of the gate cut structure includes extensions, where a first extension extends into one of the caps on a first side of the gate cut structure, and a second extension extends into the inter-gate insulator on a second side of the gate cut structure.

Abstract: A method of forming transistor devices with an air gap in the replacement gate structure is disclosed including forming a placeholder gate structure above a semiconductor material region, forming a sidewall spacer adjacent the placeholder gate structure, removing the placeholder gate structure to define a gate cavity bounded by the sidewall spacer, forming a gate insulation layer in the gate cavity, the gate insulation layer including a first portion having a first thickness and a second portion having a second thickness greater than the first thickness, forming a gate electrode in the gate cavity above the gate insulation layer, removing at least a portion of the second portion of the gate insulation layer to define an air gap cavity adjacent the gate electrode, and forming a first gate cap layer above the gate electrode, wherein the first gate cap layer seals an upper end of the air gap cavity.

Abstract: This disclosure is directed to an integrated circuit (IC) structure. The IC structure may include a semiconductor structure including two source/drain regions; a metal gate positioned on the semiconductor structure adjacent to and between the source/drain regions; a metal cap with a different metal composition than the metal gate and having a thickness in the range of approximately 0.5 nanometer (nm) to approximately 5 nm positioned on the metal gate; a first dielectric cap layer positioned above the semiconductor structure; an inter-layer dielectric (ILD) positioned above the semiconductor structure and laterally abutting both the metal cap and the metal gate, wherein an upper surface of the ILD has a greater height above the semiconductor structure than an upper surface of the metal gate; a second dielectric cap layer positioned on the ILD and above the metal cap; and a contact on and in electrical contact with the metal cap.

Abstract: A device is formed including fins formed above a substrate, an isolation structure between the fins, a plurality of structures defining gate cavities, and a first dielectric material positioned between the structures. A patterning layer above the first dielectric material and in the gate cavities has a first opening positioned above a first gate cavity exposing a portion of the isolation structure and defining a first recess, a second opening above a second gate cavity exposing a first portion of the fins, and a third opening above a first portion of a source/drain region in the fins to expose the first dielectric material. Using the patterning layer, a second recess is formed in the substrate and a third recess is defined in the first dielectric material. A second dielectric material is formed in the recesses to define a gate cut structure, a diffusion break structure, and a contact cut structure.

Abstract: Various processes form different structures including exemplary apparatuses that include (among other components) a first layer having channel regions, source/drain structures in the first layer on opposite sides of the channel regions, a gate insulator on the channel region, and a gate stack on the gate insulator. The gate stack can include a gate conductor, and a stack insulator or a gate contact on the gate conductor. The gate stack has lower sidewalls adjacent to the source/drain structures and upper sidewalls distal to the source/drain structures. Further, lower spacers are between the source/drain contacts and the lower sidewalls of the gate stack; and upper spacers between the source/drain contacts and the upper sidewalls of the gate stack. In some structures, the upper spacers can partially overlap the lower spacers.

Abstract: Parallel fins are formed (in a first orientation), and source/drain structures are formed in or on the fins, where channel regions of the fins are between the source/drain structures. Parallel gate structures are formed to intersect the fins (in a second orientation perpendicular to the first orientation), source/drain contacts are formed on source/drain structures that are on opposite sides of the gate structures, and caps are formed on the source/drain contacts. After forming the caps, a gate cut structure is formed interrupting the portion of the gate structure that extends between adjacent fins. The upper portion of the gate cut structure includes extensions, where a first extension extends into one of the caps on a first side of the gate cut structure, and a second extension extends into the inter-gate insulator on a second side of the gate cut structure.

Abstract: A method of forming transistor devices with an air gap in the replacement gate structure is disclosed including forming a placeholder gate structure above a semiconductor material region, forming a sidewall spacer adjacent the placeholder gate structure, removing the placeholder gate structure to define a gate cavity bounded by the sidewall spacer, forming a gate insulation layer in the gate cavity, the gate insulation layer including a first portion having a first thickness and a second portion having a second thickness greater than the first thickness, forming a gate electrode in the gate cavity above the gate insulation layer, removing at least a portion of the second portion of the gate insulation layer to define an air gap cavity adjacent the gate electrode, and forming a first gate cap layer above the gate electrode, wherein the first gate cap layer seals an upper end of the air gap cavity.

Abstract: Various processes form different structures including exemplary apparatuses that include (among other components) a first layer having channel regions, source/drain structures in the first layer on opposite sides of the channel regions, a gate insulator on the channel region, and a gate stack on the gate insulator. The gate stack can include a gate conductor, and a stack insulator or a gate contact on the gate conductor. The gate stack has lower sidewalls adjacent to the source/drain structures and upper sidewalls distal to the source/drain structures. Further, lower spacers are between the source/drain contacts and the lower sidewalls of the gate stack; and upper spacers between the source/drain contacts and the upper sidewalls of the gate stack. In some structures, the upper spacers can partially overlap the lower spacers.

Abstract: The present disclosure relates to methods for forming fill materials in trenches having different widths and related structures. A method may include: forming a first fill material in a first and second trench where the second trench has a greater width than the first trench; removing a portion of the first fill material from each trench and forming a second fill material over the first fill material; removing a portion of the first and second fill material within the second trench; and forming a third fill material in the second trench. The structure may include a first fill material in trenches having different widths wherein the upper surfaces of the first fill material in each trench are substantially co-planar. The structure may also include a second fill material on the first fill material in each trench, the second fill material having a substantially equal thickness in each trench.

Abstract: The present disclosure relates to semiconductor structures and, more particularly, to a hybrid fin cut with improved fin profiles and methods of manufacture. The structure includes: a plurality of fin structures in a first region of a first density of fin structures; a plurality of fin structures in a second region of a second density of fin structures; and a plurality of fin structures in a third region of a third density of fin structures. The first density, second density and third density of fin structures are different densities of fin structures, and the plurality of fin structures in the first region, the second region and the third region have a substantially uniform profile.

Abstract: One illustrative example of an overlay mark disclosed herein includes four quadrants (I-IV). Each quadrant of the mark contains an inner periodic structure and an outer periodic structure. Each of the outer periodic structures includes a plurality of outer features. Each of the inner periodic structures includes a plurality of first inner groups, each of the first inner groups having a plurality of first inner features, each first inner group being oriented such that there is an end-to-end spacing relationship between each first inner group and a selected one of the outer features.

Abstract: The present disclosure relates to semiconductor structures and, more particularly, to chamfered replacement gate structures and methods of manufacture. The structure includes: a recessed gate dielectric material in a trench structure; a plurality of recessed workfunction materials within the trench structure on the recessed gate dielectric material; a plurality of additional workfunction materials within the trench structure and located above the recessed gate dielectric material and the plurality of recessed workfunction materials; a gate metal within the trench structure and over the plurality of additional workfunction materials, the gate metal and the plurality of additional workfunction materials having a planar surface below a top surface of the trench structure; and a capping material over the gate metal and the plurality of additional workfunction materials.

Abstract: The present disclosure relates to semiconductor structures and, more particularly, to scaled memory structures with middle of the line cuts and methods of manufacture The structure comprises: a plurality of fin structures formed on a substrate; a plurality of gate structures spanning over adjacent fin structures; a cut in adjacent epitaxial source/drain regions; and a cut in contact material formed adjacent to the plurality of gate structures, which provides separate contacts.

Abstract: In conjunction with a replacement metal gate (RMG) process for forming a fin field effect transistor (FinFET), gate isolation methods and associated structures leverage the formation of distinct narrow and wide gate cut regions in a sacrificial gate. The formation of a narrow gate cut between closely-spaced fins can decrease the extent of etch damage to interlayer dielectric layers located adjacent to the narrow gate cut by delaying the deposition of such dielectric layers until after formation of the narrow gate cut opening. The methods and resulting structures also decrease the propensity for short circuits between later-formed, adjacent gates.

Abstract: A methodology for forming a single diffusion break structure in a FinFET device involves localized, in situ oxidation of a portion of a semiconductor fin. Fin oxidation within a fin cut region may be preceded by the formation of epitaxial source/drain regions over the fin, as well as by a gate cut module, where portions of a sacrificial gate that straddle the fin are replaced by an isolation layer. Localized oxidation of the fin enables the stress state in adjacent, un-oxidized portions of the fin to be retained, which may beneficially impact carrier mobility and hence conductivity within channel portions of the fin.

Abstract: Methods form an integrated circuit structure that includes complementary transistors on a first layer. An isolation structure is between the complementary transistors. Each of the complementary transistors includes source/drain regions and a gate conductor between the source/drain regions, and insulating spacers are between the gate conductor and the source/drain regions in each of the complementary transistors. With these methods and structures, an etch stop layer is formed only on the source/drain regions.

Abstract: A device is formed including fins formed above a substrate, an isolation structure between the fins, a plurality of structures defining gate cavities, and a first dielectric material positioned between the structures. A patterning layer above the first dielectric material and in the gate cavities has a first opening positioned above a first gate cavity exposing a portion of the isolation structure and defining a first recess, a second opening above a second gate cavity exposing a first portion of the fins, and a third opening above a first portion of a source/drain region in the fins to expose the first dielectric material. Using the patterning layer, a second recess is formed in the substrate and a third recess is defined in the first dielectric material. A second dielectric material is formed in the recesses to define a gate cut structure, a diffusion break structure, and a contact cut structure.

Abstract: One illustrative FinFET device disclosed herein includes a source/drain structure that, when viewed in a cross-section taken through the fin in a direction corresponding to the gate width (GW) direction of the device, comprises a perimeter and a bottom surface. The source/drain structure also has an axial length that extends in a direction corresponding to the gate length (GL) direction of the device. The device also includes a metal silicide material positioned on at least a portion of the perimeter of the source/drain structure for at least a portion of the axial length of the source/drain structure and on at least a portion of the bottom surface of the source/drain structure for at least a portion of the axial length of the source/drain structure.