A typical integrated-circuit fabrication requires interconnecting millions of
microscopic
transistors and resistors with aluminum wires. Yet, aluminum wires have greater
electrical resistance and are less reliable than copper wires. Unfortunately, current
techniques for making copper wires are time-consuming and inefficient. Accordingly,
the invention provides a method of making wires or interconnects from copper or
other metals. One embodiment entails forming a first diffusion barrier inside a
trench using ionized-magnetron sputtering for better conformal coating of the trench,
and a second diffusion barrier outside the trench using jet-vapor deposition. The
jet-vapor deposition has an acute angle of incidence which prevents deposition
within the trench and thus eliminates conventional etching steps that would otherwise
be required to leave the trench free of this material. After formation of the two
diffusion barriers, the trench is filled with metal and annealed.