Method for forming a semiconductor device including replacing material of dummy gate stacks with other conductive material

1. A method for forming a semiconductor device, comprising:

forming at least two gate stacks and respective sidewall spacers on a semiconductor substrate, wherein all of the gate stacks are formed on active regions and isolation regions, each of the gate stacks comprises a gate dielectric layer and a dummy gate, the dummy gate is formed on the semiconductor substrate, and the gate dielectric layer is sandwiched between the dummy gates and the semiconductor substrate, wherein the sidewall spacers surround both of the respective dummy gate and the respective gate dielectric layer, or the sidewall spacers are formed on the respective gate dielectric layer and surround the respective dummy gate;

forming a material layer, which exposes the dummy gates and the sidewall spacers and fills spaces between two adjacent ones of the gate stacks, wherein the material of the material layer is the same as the material of the dummy gate;

removing the dummy gates and the material layer at the same time to form recesses;

filling the recesses with a conductive material, and planarizing the conductive material to expose the sidewall spacers; and

breaking the conductive material outside the sidewall spacers to form at least two conductors, each of the conductors being only in contact with the active region at one side outside one of the sidewall spacers, so as to form gate stack structures and first contacts at the same time.

2. The method according to claim 1 , wherein the material of the material layer and the material of the dummy gate comprises polysilicon or amorphous silicon which are doped or undoped.

3. The method according to claim 2 , wherein the step for filling the recesses comprises:

forming a first contact layer which covers the bottom and sidewalls of the recesses; and

forming a first conductive layer which covers the first contact layer.

4. The method according to claim 3 , wherein when the first contact layer comprises at least one material selected from the group consisting of TiN and TiAlN, the first conductive layer comprises at least one material selected from the group consisting of W, Al, and TiAl, and a combination of Cu with W, Al or TiAl.

5. The method according to claim 1 , further comprising:

forming a planarized dielectric layer which covers the gate stack structures and the first contacts;

forming contact vias in the planarized dielectric layer, wherein the contact vias expose a portion of the first contacts;

forming a second contact layer which covers the bottom and sidewalls of the contact vias;

forming a second conductive layer which covers the second contact layer and fills the contact vias to form second contacts.

6. The method according to claim 5 , wherein the second contact layer comprises at least one material selected from the group consisting of TiN, TiAlN, TaN, TaAlN, and TaC, and the second conductive layer comprises at least one material selected from the group consisting of W, Al, Cu, and TiAl.

7. A method for forming a semiconductor device, comprising:

forming at least two gate stacks on a semiconductor substrate, wherein all of the gate stacks are formed on active regions and isolation regions, each of the gate stacks comprises a gate dielectric layer and a dummy gate, the dummy gate is formed on the semiconductor substrate, and the gate dielectric layer is sandwiched between the dummy gates and the semiconductor substrate;

forming a mask layer which surrounds the gate stacks and exposes at least a portion of the active region to form a contact region;

forming a material layer which fills the contact region and exposes the dummy gates and the mask layer, wherein the material of the material layer is the same as the material of the dummy gates;

removing the dummy gates and the material layer at the same time to form recesses; and

filling the recesses with a conductive material, and planarizing the conductive material to expose the mask layer and to form gate stack structures and a first contact at the same time.

8. The method according to claim 7 , wherein the material of the material layer and the material of the dummy gate is polysilicon or amorphous silicon which are doped or undoped.

9. The method according to claim 8 , wherein the step for filling the recess comprises:

forming a first contact layer which covers the bottom and the sidewalls of the recess; and

forming a first conductive layer which covers the first contact layer.

10. The method according to claim 9 , wherein the first contact layer comprises at least one material selected from the group consisting of TiN and TiAlN, the first conductive layer comprises at least one material selected from the group consisting of W, Al, and TiAl, and a combination of Cu with W, Al or TiAl.

11. The method according to claim 7 , further comprising:

forming a planarized dielectric layer which covers the gate stack structure and the first contact;

forming a contact via in the planarized dielectric layer, wherein the contact via exposes a portion of the first contact;

forming a second contact layer which covers the bottoms and sidewalls of the contact via; and

forming a second conductive layer which covers the second contact layer and fills the contact via to form a second contact.

12. The method according to claim 11 , wherein the second contact layer comprises at least one material selected from the group consisting of TiN, TiAlN, TaN, TaAlN, and TaC, and the second conductive layer comprises at least one material selected from the group consisting of W, Al, Cu, and TiAl.