Method for fabricating a metal gate electrode

1. A method for fabricating a metal gate electrode, said method comprising:

providing a substrate having thereon a dielectric layer and a trench in the dielectric layer;

depositing a work-function metal layer over the dielectric layer and into the trench, wherein depositing the work-function metal layer into the trench comprises forming a substantially flat layer across a bottom of the trench and forming a narrowing overhang protruding over the trench on a top surface of the dielectric layer, and the work-function metal layer is in direct contact with the top surface of the dielectric layer;

depositing a sacrificial layer over the work-function metal layer to fill the trench;

performing a chemical mechanical polishing (CMP) to remove the work-function metal layer and the sacrificial layer outside the trench such that a top surface of the sacrificial layer is co-planar with the top surface of the dielectric layer, wherein performing the CMP removes an entirety of the narrowing overhang, and the CMP stops at the top surface of the dielectric layer;

removing the sacrificial layer in the trench; and

depositing a signal metal layer to fill the trench.

2. The method of claim 1 further comprising:

performing a planarization process to planarize the signal metal layer after filling the trench.

3. The method of claim 1 , wherein:

a width of the trench is in the range of 10 to 30 nm.

4. The method of claim 1 , wherein depositing said sacrificial layer to fill the trench prevents a polish slurry used during the CMP from entering the trench.

5. The method of claim 1 , wherein the trench is formed by removing a dummy gate electrode formed in the dielectric layer.

6. The method of claim 1 , wherein said CMP stops when reaching the dielectric layer.

7. The method of claim 1 , wherein the sacrificial layer comprises a material selected from the group consisting of poly-silicon, photo-resist (PR) or Spin-on glass (SOG).

8. The method of claim 1 , wherein said removing the sacrificial layer in the trench is performed using a wet etching process.

9. The method of claim 8 , wherein the wet etching process comprises removing the sacrificial layer comprising SOG in the trench by an etching solution comprising HF.

10. The method of claim 1 , wherein said removing the sacrificial layer in the trench is performed using a dry etching process.

11. The method of claim 10 , wherein the dry etching process is performed using F, Cl, and Br based etchants.

12. A method for fabricating a metal gate electrode, said method comprising:

providing a substrate having thereon a dielectric layer and a first trench and a second trench in the dielectric layer;

depositing a work-function metal layer over the dielectric layer and into the first trench and the second trench, wherein depositing the work-function metal layer comprises forming a narrowing overhang, and the work-function metal layer is in direct contact with a top surface of the dielectric layer;

depositing a sacrificial layer over the work-function metal layer to fill the first trench and the second trench;

performing a chemical mechanical polishing (CMP) to remove the work-function metal layer and the sacrificial layer outside the trenches such that a top surface of the sacrificial layer is co-planar with the top surface of the dielectric layer, wherein performing the CMP removes an entirety of the narrowing overhang, and the CMP stops at the top surface of the dielectric layer;

removing the sacrificial layer in at least one of the first trench or the second trench to expose the work-function metal layer; and

depositing a signal metal layer to fill the at least one trench having the exposed work-function metal layer.

13. The method of claim 12 , wherein the first trench has a first aspect ratio and the second trench has a second aspect ratio different than the first aspect ratio.

14. The method of claim 12 , wherein depositing the work-function metal layer comprises depositing a multi-layered work-function metal layer.

15. The method of claim 12 , wherein depositing the signal metal layer comprises depositing a multi-layered signal metal layer.

16. The method of claim 12 , wherein depositing the work-function metal layer comprises depositing a layer having a thickness from 1 nanometer (nm) to 5 nm.

17. A method for fabricating a metal gate electrode, said method comprising:

providing a substrate having thereon a dielectric layer;

forming a trench in the dielectric layer;

depositing a gate dielectric layer into the trench;

depositing a work-function metal layer over the dielectric layer and into the trench, wherein depositing the work-function metal layer comprises forming a narrowing overhang extending beyond the work-function metal layer on sidewalls of the trench, and the work-function metal layer is in direct contact with a top surface of the dielectric layer;

depositing a sacrificial layer over the work-function metal layer to fill the first trench;

performing a chemical mechanical polishing (CMP) to remove the work-function metal layer and the sacrificial layer outside the trench such that a top surface of the sacrificial layer is co-planar with the top surface of the dielectric layer, wherein performing the CMP removes an entirety of the narrowing overhang, and the CMP stops at the top surface of the dielectric layer;

removing the sacrificial layer in the trench; and

depositing a signal metal layer to fill the trench.

18. The method of claim 17 , wherein depositing the gate dielectric layer comprises depositing a high-k dielectric layer using at least one of atomic layer deposition (ALD), chemical vapor depositing (CVD), physical vapor deposition (PVD), thermal oxidation, or ultra-violet (UV)-ozone oxidation.

19. The method of claim 18 , wherein forming the trench comprises forming a plurality of trenches.

20. The method of claim 19 , wherein forming the plurality of trenches comprises forming at least one trench of the plurality of trenches having a different width than another trench of the plurality of trenches.