IMPROVING GAP FILL OF METAL STACK IN REPLACEMENT GATE PROCESS

摘要

A method for fabricating a semiconductor device comprises forming a replacement gate structure on a semiconductor layer of a substrate. The replacement gate structure at least including a polysilicon layer. After forming the replacement gate structure, a gate spacer is formed on the replacement gate structure. Atoms are implanted in an upper portion of the polysilicon layer. The implanting expands the upper portion of the polysilicon layer and a corresponding upper portion of the gate spacer in at least a lateral direction beyond a lower portion of the polysilicon layer and a lower portion of the spacer, respectively. After the atoms have been implanted, the polysilicon layer is removed to form a gate cavity. A metal gate stack is formed within the gate cavity. The metal gate stack includes an upper portion having a width that is greater than a width of a lower portion of the metal gate stack.