Semiconductor devices and methods of manufacture thereof

1. A method of manufacturing a semiconductor device, the method comprising:

providing a workpiece including a gate dielectric and a gate disposed over the gate dielectric;

reshaping a top surface of the gate to form a gate with a rounded profile; and

etching a via and forming a contact therein, wherein the contact is disposed on at least a portion of the rounded profile of the gate.

2. The method according to claim 1 , wherein the gate comprises a first conductive material disposed over the gate dielectric and a second conductive material disposed over the first conductive material, and wherein reshaping the top surface of the gate comprises recessing the second conductive material.

3. The method according to claim 2 , wherein recessing the second conductive material comprises an etch process that comprises an etch chemistry selected from the group consisting essentially of Cl 2 , BCl 3 , and combinations thereof.

4. The method according to claim 2 , further comprising recessing the first conductive material.

5. The method according to claim 4 , wherein recessing the first conductive material comprises an etch process that comprises an etch chemistry selected from the group consisting essentially of SF 6 , O 2 , NF 3 , CF 4 , and combinations thereof.

6. The method according to claim 2 , wherein recessing the second conductive material comprises an etch process comprising a flow rate of about 10 standard cubic centimeters per minute (s.c.c.m.) to about 200 s.c.c.m.

7. The method according to claim 2 , wherein recessing the second conductive material comprises an etch process comprising a pressure of about 1 mT to about 30 mT.

8. The method according to claim 2 , wherein recessing the second conductive material comprises an etch process comprising a chuck temperature of about 30 degrees C. to about 60 degrees C. or chamber wall temperature of about 50 degrees C. to about 90 degrees C.

9. A method of manufacturing a semiconductor device, the method comprising:

forming a plurality of fins over a workpiece;

forming an insulating material over the plurality of fins;

removing the insulating material between two of the plurality of fins to form a patterned insulating material;

forming a dielectric material over sidewalls and a top surface of the insulating material and over a portion of the workpiece between the two of the plurality of fins;

forming a first conductive material over the dielectric material;

forming a second conductive material over the first conductive material; and

recessing the first conductive material and the second conductive material, wherein recessing the second conductive material comprises reshaping a top surface of the second conductive material to form a rounded profile of the second conductive material, and wherein the first conductive material and the second conductive material comprise a gate of a transistor.

10. The method according to claim 9 , wherein forming the second conductive material comprises overfilling a space in the insulating material between the two of the plurality of fins; and wherein the method further comprises chemically-mechanically polishing or etching the insulating material after forming the second conductive material, leaving the first conductive material and the second conductive material within the patterned insulating material.

11. The method according to claim 9 , wherein the insulating material comprises a first insulating material, and wherein the method further comprises forming a second insulating material over the second conductive material after recessing the first conductive material and the second conductive material.

12. The method according to claim 11 , further comprising forming a third insulating material over the first insulating material and the second insulating material, and forming a contact in the third insulating material and the second insulating material, wherein the contact is coupled to the second conductive material of the gate.

13. The method according to claim 9 , wherein forming the first conductive material comprises forming a work function metal comprising a plurality of material layers.

14. The method according to claim 9 , wherein recessing the first conductive material and the second conductive material comprises an etch process that comprises an etch chemistry selected from the group consisting essentially of SF 6 , O 2 , NF 3 , CF 4 , and combinations thereof.

15. The method according to claim 9 , wherein recessing the second conductive material comprises an etch process comprising a flow rate of about 10 standard cubic centimeters per minute (s.c.c.m.) to about 200 s.c.c.m.

16. The method according to claim 9 , wherein recessing the second conductive material comprises an etch process comprising a pressure of about 1 mT to about 30 mT.

17. A method of manufacturing a semiconductor device, the method comprising:

forming a fin on a semiconductor substrate;

forming a gate structure on the fin, the gate structure including a dielectric layer and a metal layer, the metal layer having a substantially planar top surface; and

etching the metal layer to form a top surface having a convex shape.

18. The method according to claim 17 , wherein the metal layer comprises a first metal sub-layer of a first material and a second metal sub-layer of a second material different from the first material, the first metal sub-layer being interjacent the dielectric layer and the second metal sub-layer.

19. The method according to claim 17 , wherein etching the metal layer comprises an etch process using an etch chemistry selected from the group consisting of SF 6 , O 2 , NF 3 , CF 4 , and combinations thereof.

20. The method according to claim 18 , wherein the second metal sub-layer comprises Cu.