A method of forming barrier layers in a via hole extending through an inter-level
dielectric layer and including a preformed first barrier coated onto the bottom
and sidewalls of the via holes. In a single plasma sputter reactor, a first step
sputters the wafer rather than the target with high energy ions to remove the barrier
layer from the bottom of the via but not from the sidewalls and a second step sputter
deposits a second barrier layer, for example of Ta/TaN, onto the via bottom and
sidewalls. The two steps may be differentiated by power applied to the target,
by chamber pressure, or by wafer bias. The second step may include the simultaneous
removal of the first barrier layer from the via bottom and sputter deposition of
the second barrier layer onto the via sidewalls.