Method and structures are provided for conformal lining of dual damascene
structures in integrated circuits, and particularly of openings formed in
porous materials. Trenches and contact vias are formed in insulating
layers. The pores on the sidewalls of the trenches and vias are blocked,
and then the structure is exposed to alternating chemistries to form
monolayers of a desired lining material. In exemplary process flows
chemical or physical vapor deposition (CVD or PVD) of a sealing layer
blocks the pores due to imperfect conformality, and is followed by an
atomic layer deposition (ALD), particularly alternately pulsed metal
halide and ammonia gases injected into a constant carrier flow. An
alternating process can also be arranged to function in CVD-mode within
pores of the insulator, since the reactants do not easily purge from the
pores between pulses. Self-terminated metal layers are thus reacted with
nitrogen. Near perfect step coverage allows minimal thickness for a
diffusion barrier function, thereby maximizing the volume of a subsequent
filling metal for any given trench and via dimensions.