Cu electroplating on an ultrathin Co seed has been developed for superconformal filling of advanced interconnects, in an acidic CuSO4 electrolyte containing plating additives, i.e., halide, suppressor, accelerator, and leveler. A suppressor-halide adlayer is found to play a bifunctional role in both suppressing Cu growth and inhibiting Co dissolution. Corrosion inhibition is attributed to adsorption of hydrophobic suppressor molecules on a halide-terminated Co surface that blocks water from interacting with Co, thereby retarding the formation of Co(OH)+, a corrosion immediate with which hydronium from the electrolyte would react to form soluble Co2+. With enhanced suppression, Co loss is mainly confined to the removal of native Co oxides in acid. Correspondingly, galvanic Cu deposition forms a monolayer shortly after immersion at open-circuit potential, becoming self-terminated with growth of a second layer over the next 20 s as dynamic surface processes make more underlying Co available for the displacement reaction. Growth of the first Cu layer is controlled by the receding of native oxides in an exponential-decay manner. Native Co oxides, if not removed, promote Cu protrusions in electroplating. The proposed process produces void-free fill on a 22 nm wide feature with a Co liner about 20 Å thick after fill.
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