A method for forming a transistor including a self aligned metal gate is
provided. According to various method embodiments, a high-k gate
dielectric is formed on a substrate and a sacrificial carbon gate is
formed on the gate dielectric. Sacrificial carbon sidewall spacers are
formed adjacent to the sacrificial carbon gate, and source/drain regions
for the transistor are formed using the sacrificial carbon sidewall
spacers to define the source/drain regions. The sacrificial carbon
sidewall spacers are replaced with non-carbon sidewall spacers, and the
sacrificial carbon gate is replaced with a desired metal gate material to
provide the desired metal gate material on the gate dielectric. Various
embodiments form source/drain extensions after removing the carbon
sidewall spacers and before replacing with non-carbon sidewall spacers.
An etch barrier is used in various embodiments to separate the
sacrificial carbon gate from the sacrificial carbon sidewall spacers.
Other aspects and embodiments are provided herein.