Abstract: Commonly fabricated FinFET type semiconductor devices with different (i.e., both taller and shorter) heights of an entirety of or only the channel region of some of the fins. Where only the channel of some of the fins has a different height, the sources and drains have a common height higher than those channels. The different fin heights are created by recessing some of the fins, and where only the channels have different heights, the difference is created by exposing a top surface of each channel intended to be shorter, the other channels being masked, and partially recessing the exposed channel(s). In both cases, the mask(s) may then be removed and conventional FinFET processing may proceed.

Abstract: One illustrative method disclosed herein includes, among other things, forming a composite fin structure that is comprised of a first germanium-containing semiconductor material having a first concentration of germanium and a tensile-strained second semiconductor material (having a lesser germanium concentration) positioned on the first germanium-containing semiconductor material and performing a thermal anneal process to convert the first germanium-containing semiconductor material portion of the composite fin structure into a germanium-containing oxide isolation region positioned under the second semiconductor material that is a tensile-strained final fin for an NMOS FinFET device.

Abstract: A method includes forming at least one fin on a semiconductor substrate. A silicon alloy material is formed on the fin and on exposed surface portions of the substrate. A thermal process is performed to define a silicon alloy fin from the silicon alloy material and the fin and to define silicon alloy surface portions from the silicon alloy material and the exposed surface portions of the substrate. A semiconductor device includes a substrate, a fin defined on the substrate, the fin comprising a silicon alloy and having a substantially vertical sidewall, and silicon alloy surface portions on the substrate adjacent the fin.

Abstract: One method of forming epi semiconductor cladding materials in the channel region of a semiconductor device is disclosed which includes forming a sacrificial gate structure around a portion of an initial fin, forming a sidewall spacer adjacent opposite sides of the sacrificial gate structure and removing the sacrificial gate structure so as to thereby define a replacement gate cavity, performing an etching process through the replacement gate cavity to remove portions of the initial fin so as to thereby define a reduced size fin and recesses under the sidewall spacers, forming at least one replacement epi semiconductor cladding material around the reduced size fin in the replacement gate cavity and in the recesses under the sidewall spacers, and forming a replacement gate structure within the replacement gate cavity around the at least one replacement epi semiconductor cladding material.

Abstract: Semiconductor structures and fabrication methods are provided which includes, for instance, fabricating a semiconductor fin structure by: providing a fin structure extending above a substrate, the fin structure including a first fin portion, a second fin portion disposed over the first fin portion, and an interface between the first and the second fin portions, where the first fin portion and the second fin portion are lattice mismatched within the fin structure; and modifying, in part, the fin structure to obtain a modified fin structure, the modifying including selectively oxidizing the interface to form an isolation region within the modified fin structure, where the isolation region electrically insulates the first fin portion from the second fin portion, while maintaining structural stability of the modified fin structure.

Abstract: A method includes forming at least one fin on a semiconductor substrate. A silicon alloy material is formed on the fin and on exposed surface portions of the substrate. A thermal process is performed to define a silicon alloy fin from the silicon alloy material and the fin and to define silicon alloy surface portions from the silicon alloy material and the exposed surface portions of the substrate. A semiconductor device includes a substrate, a fin defined on the substrate, the fin comprising a silicon alloy and having a substantially vertical sidewall, and silicon alloy surface portions on the substrate adjacent the fin.

Abstract: A modified silicon substrate having a substantially defect-free strain relaxed buffer layer of SiGe is suitable for use as a foundation on which to construct a high performance CMOS FinFET device. The substantially defect-free SiGe strain-relaxed buffer layer can be formed by making cuts in, or segmenting, a strained epitaxial film, causing edges of the film segments to experience an elastic strain relaxation. When the segments are small enough, the overall film is relaxed so that the film is substantially without dislocation defects. Once the substantially defect-free strain-relaxed buffer layer is formed, strained channel layers can be grown epitaxially from the relaxed SRB layer. The strained channel layers are then patterned to create fins for a FinFET device. In one embodiment, dual strained channel layers are formed—a tensilely strained layer for NFET devices, and a compressively strained layer for PFET devices.

Abstract: One method of forming epi semiconductor cladding materials in the channel region of a semiconductor device is disclosed which includes forming an initial epi semiconductor cladding material around the exposed portion of a fin for an entire axial length of the fin, forming a sacrificial gate structure around a portion of the fin and the initial cladding material, removing the sacrificial gate structure so as to thereby define a replacement gate cavity, performing an etching process through the replacement gate cavity to remove at least the exposed portion of the initial cladding material and thereby expose a surface of the fin within the replacement gate cavity, forming at least one replacement epi semiconductor cladding material around the exposed surface of the fin, and forming a replacement gate structure within the replacement gate cavity around the at least one replacement epi semiconductor cladding material.

Abstract: One method of forming epi semiconductor cladding materials in the channel region of a semiconductor device is disclosed which includes forming an initial epi semiconductor cladding material around the exposed portion of a fin for an entire axial length of the fin, forming a sacrificial gate structure around a portion of the fin and the initial cladding material, removing the sacrificial gate structure so as to thereby define a replacement gate cavity, performing an etching process through the replacement gate cavity to remove at least the exposed portion of the initial cladding material and thereby expose a surface of the fin within the replacement gate cavity, forming at least one replacement epi semiconductor cladding material around the exposed surface of the fin, and forming a replacement gate structure within the replacement gate cavity around the at least one replacement epi semiconductor cladding material.

Abstract: The present disclosure is directed to forming relatively abrupt junctions between the channel region and source/drain regions of a PMOS transistor device with a germanium-containing channel region. A liner layer is formed in previously formed source/drain cavities prior to the formation of epi semiconductor material in the source/drain cavities above the liner layer. The materials for the liner layer and, particularly, the concentration of germanium (if any is present) are adjusted relative to the germanium concentration in the channel region and the epi source/drain material such that, during an anneal process, dopant materials (e.g., boron) that diffuse from the source/drain region during the anneal process tend to accumulate in or near the liner layer.

Abstract: A method of creating a virtual relaxed substrate includes providing a bulk semiconductor substrate, and creating a layer of strained semiconductor material on the substrate, a non-zero lattice mismatch of less than about 2% being present between the substrate and the layer of strained semiconductor material, and the layer of strained semiconductor material having a thickness of from about 50 nm to about 150 nm. The method further includes etching through the layer of strained semiconductor material and into the substrate to create shaped pillars separated by slits and sized to achieve edge effect relaxation throughout each shaped pillar, merging a top portion of the pillars with single crystal growth of epitaxial material to create a continuous surface while substantially maintaining the slits, and creating a virtual relaxed substrate by creating a layer of epitaxial composite semiconductor material over the continuous surface.

Abstract: A method includes forming a fin on a semiconductor substrate and forming recesses on sidewalls of the fin. A silicon alloy material is formed in the recesses. A thermal process is performed to define a silicon alloy fin portion from the silicon alloy material and the fin. A semiconductor device includes a substrate, a fin defined on the substrate and an isolation structure disposed adjacent the fin. A first portion of the fin extending above the isolation structure has a substantially vertical sidewall and a different material composition than a second portion of the fin not extending above the isolation structure.

Abstract: One illustrative method disclosed herein includes, among other things, performing first and second in situ doping, epitaxial deposition processes to form first and second layers of in situ doped epi semiconductor material, respectively, above a semiconductor substrate, wherein one of the first and second layers has a high level of germanium and a low level of P-type dopant material and the other of the first and second layers has a low level of germanium and a high level of P-type dopant material, and performing a mixing thermal anneal process on the first and second layers so as to form the final silicon germanium material having a high level of germanium and a high level of P-type dopant material.

Abstract: A method of forming a semiconductor structure includes forming a first isolation region between fins of a first group of fins and between fins of a second group of fins. The first a second group of fins are formed in a bulk semiconductor substrate. A second isolation region is formed between the first group of fins and the second group of fins, the second isolation region extends through a portion of the first isolation region such that the first and second isolation regions are in direct contact and a height above the bulk semiconductor substrate of the second isolation region is greater than a height above the bulk semiconductor substrate of the first isolation region.

Abstract: One illustrative method includes, among other things, forming a plurality of trenches in a semiconductor substrate so as to define a substrate fin, forming a layer of insulating material in the trenches, and forming a layer of CTE-matching material above the upper surface of the layer of insulating material, wherein the layer of CTE-matching material has a CTE that is within ±20% of the replacement fin CTE and wherein the layer of CTE-matching material partially defines a replacement fin cavity that exposes an upper portion of the substrate fin. In this example, the method also includes forming the replacement fin on the substrate fin and in the replacement fin cavity, removing the layer of CTE-matching material and forming a gate structure around at least a portion of the replacement fin.

Abstract: Various methods are disclosed herein for forming alternative fin materials that are in a stable or metastable condition. In one case, a metastable replacement fin is grown to a height that is greater than an unconfined stable critical thickness of the replacement fin material and it has a defect density of 105 defects/cm2 or less throughout at least 90% of its entire height. In another case, a metastable replacement fin is grown to a height that is greater than an unconfined metastable critical thickness of the replacement fin material and it has a defect density of 105 defects/cm2 or less throughout at least 90% of its entire height.

Abstract: A method of forming raised S/D regions by partial EPI growth with a partial EPI liner therebetween and the resulting device are provided. Embodiments include forming groups of fins extending above a STI layer; forming a gate over the groups of fins; forming a gate spacer on each side of the gate; forming a raised S/D region proximate to each spacer on each fin of the groups of fins, each raised S/D region having a top surface, vertical sidewalls, and an undersurface; forming a liner over and between each raised S/D region; removing the liner from the top surface of each raised S/D region and from in between a group of fins; forming an overgrowth region on the top surface of each raised S/D region; forming an ILD over and between the raised S/D regions; and forming a contact through the ILD, down to the raised S/D regions.

Abstract: One illustrative method disclosed herein includes, among other things, performing an epitaxial deposition process to form an epi SiGe layer above a recessed layer of insulating material and on an exposed portion of a fin, wherein the concentration of germanium in the layer of epi silicon-germanium (SixGe1-x) is equal to or greater than a target concentration of germanium for the final fin, performing a thermal anneal process in an inert processing environment to cause germanium in the epi SiGe to diffuse into the fin and thereby define an SiGe region in the fin, after performing the thermal anneal process, performing at least one process operation to remove the epi SiGe and, after removing the epi SiGe, forming a gate structure around at least a portion of the SiGe region.

Abstract: Various methods are disclosed herein for forming alternative fin materials that are in a stable or metastable condition. In one case, a stable replacement fin is grown to a height that is greater than an unconfined stable critical thickness of the replacement fin material and it has a defect density of 104 defects/cm2 or less throughout its entire height. In another case, a metastable replacement fin is grown to a height that is greater than an unconfined metastable critical thickness of the replacement fin material and it has a defect density of 105 defects/cm2 or less throughout at least 90% of its entire height.

Abstract: One illustrative device disclosed herein includes a substrate fin formed in a substrate comprised of a first semiconductor material, wherein at least a sidewall of the substrate fin is positioned substantially in a <100> crystallographic direction of the crystalline structure of the substrate, a replacement fin structure positioned above the substrate fin, wherein the replacement fin structure is comprised of a semiconductor material that is different from the first semiconductor material, and a gate structure positioned around at least a portion of the replacement fin structure.