Abstract: In a semiconductor device, through hole vias or through silicon vias (TSV) may be formed so as to include an efficient stress relaxation mechanism, for instance provided on the basis of a stress relaxation layer, in order to reduce or compensate for stress forces caused by a pronounced change in volume of the conductive fill materials of the through hole vias. In this manner, the high risk of creating cracks and delamination events in conventional semiconductor devices may be significantly reduced.

Abstract: Generally, the present disclosure is directed to forming conductive metal fill materials in replacement gate electrodes using reduced deposition temperatures. One illustrative method disclosed herein includes, among other things, forming a sacrificial gate structure above a semiconductor layer, the sacrificial gate structure including a dummy gate electrode, and forming a gate cavity by removing at least the dummy gate electrode from above the semiconductor layer. The disclosed method further includes forming a work-function material of a replacement metal gate electrode in the gate cavity, and forming a conductive metal fill material in the gate cavity and above the work-function material, wherein forming the conductive metal fill material includes performing a material deposition process at a temperature below approximately 450° C.

Abstract: Generally, the present disclosure is directed to methods for reducing line edge roughness in hardmask integration schemes that are used for forming interconnect structures, such as conductive lines and the like. One illustrative method disclosed herein includes, among other things, forming a metal hardmask above a dielectric material and forming a first opening in the metal hardmask, the first opening comprising sidewalls, and the sidewalls having a surface roughness. The disclosed method further includes reducing the surface roughness of the sidewalls, and using the first opening with the sidewalls of reduced surface roughness to form a second opening in the dielectric material.

Abstract: In sophisticated semiconductor devices, the contact elements connecting to active semiconductor regions having formed thereabove closely spaced gate electrode structures may be provided on the basis of a liner material so as to reduce the lateral width of the contact opening, while, on the other hand, non-critical contact elements may be formed on the basis of non-reduced lateral dimensions. To this end, at least a first portion of the critical contact element is formed and provided with a liner material prior to forming the non-critical contact element.

Abstract: Methods are provided for fabricating integrated circuits that include forming first and second spaced apart gate structures overlying a semiconductor substrate, and forming first and second spaced apart source/drain regions in the semiconductor substrate between the gate structures. A first layer of insulating material is deposited overlying the gate structures and the source/drain regions by a process of atomic layer deposition, and a second layer of insulating material is deposited overlying the first layer by a process of chemical vapor deposition. First and second openings are etched through the second layer and the first layer to expose portions of the source/drain regions. The first and second openings are filled with conductive material to form first and second spaced apart contacts, electrically isolated from each other, in electrical contact with the first and second source/drain regions.

Abstract: In sophisticated semiconductor devices, superior contact resistivity may be accomplished for a given contact configuration by providing hybrid contact elements, at least a portion of which may be comprised of a highly conductive material, such as copper. To this end, a well-established contact material, such as tungsten, may be used as buffer material in order to preserve integrity of sensitive device areas upon depositing the highly conductive metal.

Abstract: Disclosed herein are various methods of forming conductive structures, such as conductive lines and vias, using a dual metal hard mask integration technique. In one example, the method includes forming a first layer of insulating material, forming a first patterned metal hard mask layer above the first layer of insulating material, forming a second patterned metal hard mask layer above the first patterned metal hard mask layer, performing at least one etching process through both of the second patterned metal hard mask layer and the first patterned metal hard mask layer to define a trench in the first layer of insulating material and forming a conductive structure in the trench.

Abstract: A method of manufacturing a semiconductor device begins by fabricating an n-type metal oxide semiconductor (NMOS) transistor structure on a semiconductor wafer. The method continues by forming an optically reflective layer overlying the NMOS transistor structure, forming a layer of tensile stress inducing material overlying the optically reflective layer, and curing the layer of tensile stress inducing material by applying ultraviolet radiation. Some of the ultraviolet radiation directly radiates the layer of tensile stress inducing material and some of the ultraviolet radiation radiates the layer of tensile stress inducing material by reflecting from the optically reflective layer.

Abstract: Disclosed herein are various methods of filing voids in copper conductive structures on integrated circuit devices. In one example, the method includes the steps of forming a conductive copper structure in a layer of insulating material and performing an electroless deposition process to selectively form a fill layer comprised of a conductive material on the copper containing structure, the fill layer being adapted to at least partially fill any voids that may exist in the conductive copper structure.

Abstract: One method disclosed herein includes the steps of forming a ULK material layer, forming a hard mask layer above the ULK material layer, forming a patterned photoresist layer above the hard mask layer, performing at least one etching process to define an opening in at least the ULK material layer for a conductive structure to be positioned in at least the ULK material layer, forming a fill material such that it overfills the opening, performing a process operation to remove the patterned photoresist layer and to remove the fill material positioned outside of the opening, removing the fill material from within the opening and, after removing the fill material from within the opening, forming a conductive structure in the opening.

Abstract: In sophisticated semiconductor devices, densely packed metal line layers may be formed on the basis of an ultra low-k dielectric material, wherein corresponding modified portions of increased dielectric constant may be removed in the presence of the metal lines, for instance, by means of a selective wet chemical etch process. Consequently, the metal lines may be provided with desired critical dimensions without having to take into consideration a change of the critical dimensions upon removing the modified material portion, as is the case in conventional strategies.

Abstract: Upon forming a complex metallization system, the parasitic capacitance between metal lines of adjacent metallization layers may be reduced by providing a patterned etch stop material. In this manner, the patterning process for forming the via openings may be controlled in a highly reliable manner, while, on the other hand, the resulting overall dielectric constant of the metallization system may be reduced, thereby also significantly reducing the parasitic capacitance between stacked metal lines.

Abstract: In a dual stress liner approach, unwanted material provided between closely spaced gate electrode structures may be removed to a significant degree on the basis of a wet chemical etch process, thereby reducing the risk of creating patterning-related irregularities. Consequently, the probability of contact failures in sophisticated interlayer dielectric material systems formed on the basis of a dual stress liner approach may be reduced.

Abstract: Semiconductor devices are formed with a dielectric stack by forming an UV reflecting layer between cured and uncured ULK layers during BEOL processing. Embodiments include forming a first ultra low-k (ULK) layer on a semiconductor element, curing the first ULK layer, forming an ultraviolet (UV) reflecting layer on the first ULK layer, forming a second ULK layer on the UV reflecting layer, and irradiating the second ULK layer with UV light.

Abstract: Upon forming a complex metallization system, the parasitic capacitance between metal lines of adjacent metallization layers may be reduced by providing a patterned etch stop material. In this manner, the patterning process for forming the via openings may be controlled in a highly reliable manner, while, on the other hand, the resulting overall dielectric constant of the metallization system may be reduced, thereby also significantly reducing the parasitic capacitance between stacked metal lines.

Abstract: Integrated circuits and methods for fabricating an integrated circuit are provided. A conductive feature is formed in a semiconductor substrate. A layer of ULK or LK dielectric material is formed overlying the conductive feature. An opening having a sidewall surface is etched through the layer of ULK or LK dielectric material. Damage on the sidewall surface resulting from the etching is removed. An ULK or LK dielectric liner is formed overlying the sidewall surface. The ULK or LK dielectric liner along the bottom of the opening is removed to expose the conductive feature. The opening is filled with a metal fill material contacting the conductive feature.

Abstract: Fabrication methods for semiconductor device structures are provided. One method for fabricating a semiconductor device structure that includes a gate structure overlying a semiconductor substrate and a doped region formed in the semiconductor substrate adjacent to the gate structure involves the steps of forming a first layer of dielectric material overlying the gate structure and the doped region, isotropically etching the first layer of dielectric material, forming a second layer of dielectric material overlying the first layer of dielectric material after isotropically etching the first layer, and forming a conductive contact that is electrically connected to the doped region within the first layer and the second layer.

Abstract: In sophisticated semiconductor devices, superior contact resistivity may be accomplished for a given contact configuration by providing hybrid contact elements, at least a portion of which may be comprised of a highly conductive material, such as copper. To this end, a well-established contact material, such as tungsten, may be used as buffer material in order to preserve integrity of sensitive device areas upon depositing the highly conductive metal.

Abstract: Fabrication methods for semiconductor device structures are provided. One method for fabricating a semiconductor device structure that includes a gate structure overlying a semiconductor substrate and a doped region formed in the semiconductor substrate adjacent to the gate structure involves the steps of forming a first layer of dielectric material overlying the gate structure and the doped region, isotropically etching the first layer of dielectric material, forming a second layer of dielectric material overlying the first layer of dielectric material after isotropically etching the first layer, and forming a conductive contact that is electrically connected to the doped region within the first layer and the second layer.

Abstract: A method of manufacturing a semiconductor device begins by fabricating an n-type metal oxide semiconductor (NMOS) transistor structure on a semiconductor wafer. The method continues by forming an optically reflective layer overlying the NMOS transistor structure, forming a layer of tensile stress inducing material overlying the optically reflective layer, and curing the layer of tensile stress inducing material by applying ultraviolet radiation. Some of the ultraviolet radiation directly radiates the layer of tensile stress inducing material and some of the ultraviolet radiation radiates the layer of tensile stress inducing material by reflecting from the optically reflective layer.