A method for forming a gate structure includes forming a gate dielectric
layer on a semiconductor substrate and a metal gate conductor on the gate
dielectric layer. A cap layer is formed on the metal gate conductor. The
method provides for patterning the cap layer, the gate metal layer and
the gate dielectric layer to form a capped gate conductor. At least one
spacer is formed to cover sidewalls of the metal gate conductor and the
cap layer, such that the cap layer and the spacer encloses the metal gate
conductor layer therein. At least one self-aligned contact structure
formed next to the metal gate conductor on the semiconductor substrate.
As such, the cap layer and the spacer separate the self-aligned contact
structure from directly contacting the metal gate conductor.