A method for forming etched features in a layer of a first material is provided. A layer of a second material is deposited over the layer of the first material. An alloy layer of the first material and the second material is formed between the layer of the first material and the layer of the second material. The layer of the first material is selectively etched with respect to the alloy layer, using the alloy layer as a hardmask.

A method includes depositing a first dielectric layer over a first conductive feature, depositing a first mask layer over the first dielectric layer, and depositing a second mask layer over the first mask layer. A first opening is patterned in the first mask layer and the second mask layer, the first opening having a first width. A second opening is patterned in a bottom surface of the first opening, the second opening extending into the first dielectric layer, the second opening having a second width. The second width is less than the first width. The first opening is extended into the first dielectric layer and the second opening is extended through the first dielectric layer to expose a top surface of the first conductive feature.

A semiconductor process system includes a process chamber with a lid. The system includes a heater positioned on the lid and a controller configured to control the heater. The controller operates the heater to provide a selected temperature distribution of the lid.

Embodiments of the present disclosure relates to method of forming trench and via features using dielectric and metal mask layers. Particularly, embodiments of present disclosure provide a hard mask stack including a first dielectric mask layer, and second dielectric mask layer and a metal mask layer, wherein the first dielectric mask layer and second dielectric mask layer have a high etch selectivity.

Semiconductor devices and methods of manufacturing the semiconductor devices are described herein. A method includes forming a first etch stop layer from a portion of a gate mask, the gate mask extending between spacers adjacent a gate electrode, the gate electrode overlying a semiconductor fin. The method further includes forming a second etch stop layer adjacent the first etch stop layer, forming an opening through the second etch stop layer, and exposing the first etch stop layer by performing a first etching process. The method further includes extending the opening through the first etch stop layer and exposing the gate electrode by performing a second etching process. Once the gate electrode has been exposed, the method further includes forming a gate contact in the opening.

A method of forming a via is provided. A lower metal element is formed, and a first patterned photoresist is used to form a sacrificial element over the lower metal element. A dielectric region including a dielectric element projection extending upwardly above the sacrificial element is formed. A second patterned photoresist including a second photoresist opening is formed, wherein the dielectric element projection is at least partially located in the second photoresist opening. A dielectric region trench opening is etched in the dielectric region. The sacrificial element is removed to define a via opening extending downwardly from the dielectric region trench opening. The dielectric region trench opening and the via opening are filled to define (a) an upper metal element in the dielectric region trench opening and (b) a via in the via opening, wherein the via extends downwardly from the upper metal element.

A method for fabricating a semiconductor device includes: forming a stack body over a substrate; forming channel structures in the stack body, the channel structures comprising a channel layer penetrating the stack body; forming a contact-level dielectric layer over the stack body and the channel structures; forming a contact hole penetrating the contact-level dielectric layer; forming contact plugs in the contact hole, the contact plugs coupled to the channel layers of the channel structures; recessing the contact plugs to form upper surfaces of the contact plugs that are lower than an upper surface of the contact-level dielectric layer; forming a bit line-level dielectric layer including a spacer layer over the recessed contact plugs; etching the bit line-level dielectric layer to form trenches that expose the recessed contact plugs; and forming a bit line in one or more of the trenches.

A semiconductor device includes active regions extending in a first direction on a substrate; a gate electrode intersecting the active regions on the substrate, extending in a second direction, and including a contact region protruding upwardly; and an interconnection line on the gate electrode and connected to the contact region, wherein the contact region includes a lower region having a first width in the second direction and an upper region located on the lower region and having a second width smaller than the first width in the second direction, and wherein at least one side surface of the contact region in the second direction has a point at which an inclination or a curvature is changed between the lower region and the upper region.

A semiconductor device structure is provided. The semiconductor device structure includes a gate stack and a source/drain contact structure formed over a substrate. A first gate spacer is separated the gate stack from the source/drain contact structure and extends above top surfaces of the gate stack and the source/drain contact structure. An insulating capping layer covers the top surface of the gate stack and extends on the top surface of the first gate spacer. A conductive via structure partially covers the top surface of the insulating capping layer and the top surface of the source/drain contact structure. A first insulating layer surrounds the conductive via structure and partially covers the top surface of the source/drain contact structure.

A semiconductor device includes: an isolation insulating layer; fin structures protruding from the isolation insulating layer; gate structures, each having a metal gate and a cap insulating layer disposed over the metal gate; a first source/drain epitaxial layer and a second source/drain epitaxial layer disposed between two adjacent gate structures; and a first conductive contact disposed on the first source/drain epitaxial layer, and a second conductive contact disposed on the second source/drain epitaxial layer; a separation isolation region disposed between the first and second conductive contact; and an insulating layer disposed between the separation isolation region and the isolation insulating layer. The separation isolation region is made of a different material than the insulating layer.