Sidewall spacers are disclosed that extend on opposing sidewalls of gate
stacks. The sidewall spacers have improved profiles to suppress or
eliminate void formation between the gate stacks during gap-filling A
gate dielectric layer is formed on a semiconductor substrate. Then, a
gate stack 24 having a sidewall is formed over the gate dielectric layer.
The gate stack 24 comprises a conductive layer 28 and a hard mask 30
overlying the conductive layer 28. A liner 32 is selectively deposited
over the gate stack 24 such that the liner 32 is deposited on the hard
mask 30 at a rate lower than the rate of deposition on the conductive
layer 28. Thus, the liner 32 is substantially thinner on the hard mask 30
than on the conductive layer 28. A nitride spacer is formed over 34 the
liner 32. A PMD layer is formed over the resultant structure, filling the
gaps between adjacent gate stacks.