A continuous electroless-plated Cu film only 10 nm thick was successfully deposited on a TaN barrier over a 1-nm-thick Pd catalytic layer formed by ionized cluster beam deposition. Secondary ion mass spectrometry ͑SIMS͒ analyses for the electrolessplated Cu films on the 20-nm and 1-nm ionized cluster beam ͑ICB͒-Pd layers showed that the Pd metal had diffused into the Cu and caused a high electrical resistivity of Cu interconnect. The electrical resistivity of Cu interconnects formed by electroless plating on an ICB-deposited Pd catalyst layer decreased with decreasing thickness of the ICB-Pd layer. At an ICB-Pd layer thickness of 1-nm, the electrical resistivity of the overlying Cu interconnect was 2.11 ⍀ cm. Moreover, the deposited film has adhesion strength as high as that of sputtered Cu on TaN, even for the case of the 1-nm-thick Pd catalyst layer. A uniform and continuous 10-nm-thick Cu seed layer was formed by electroless plating over a 1-nm-thick Pd layer, and subsequent Cu electroplating filled all high-aspect-ratio via holes without the appearance of voids.Current damascene copper interconnections are fabricated by electroplating on a sputtered Cu seed layer. However, as the dimensions of interconnections continue to shrink, it is becoming increasingly difficult to form a continuous sputtered Cu film on the sidewalls of fine via holes due to the typically poor step coverage of sputtering processes, resulting in the formation of voids during electroplating. 1 Copper electroless plating and chemical vapor deposition ͑CVD͒ are promising processes for the formation of seed layers for subsequent electroplating. 2-6 Copper electroless plating, which does not require a sputtered Cu seed layer, is an efficient means of filling high-aspect-ratio holes and has become increasingly important in the industry. 3-5 Gandikota et al. and Andryuschenko and Reid reported that high-aspect via holes were filled completely by electroplating on a Cu seed layer prepared by physical vapor deposition ͑PVD͒ followed by repair by electroless copper plating. 7,8 However, the processes proved to be too complicated for practical manufacturing.The authors have investigated the formation of a Pd catalysis layer by ionized cluster beam ͑ICB͒ deposition, which provides highly directional deposition suitable for high-aspect-ratio holes. 9 Using this process, a continuous copper layer could be formed even on high-aspect-ratio holes and trenches by electroless copper plating. Furthermore, the adhesion between the electroless-plated Cu film and the TaN barrier layer was sufficient to endure chemical mechanical polishing ͑CMP͒ at an ICB-Pd layer thickness of 20 nm. 10,11 However, the electrical resistivity of the Cu damascene interconnection was rather high ͑3.5-3.9 ⍀ cm͒, thought to be due to diffusion of Pd into the overlying Cu. In this study, the effect of the thickness of the ICB-Pd layer on the properties of the overlying electroless-deposited Cu film is investigated.
ExperimentalICB-Pd films with thickness of 1-20 nm were deposited on t...