A method of forming a copper interconnect in a dual damascene scheme is described.
After a diffusion barrier layer and seed layer are sequentially formed on the sidewalls
and bottoms of a trench and via in a dielectric layer, a first copper layer is
deposited by a first ECP process at a 10 mA/cm2 current density to fill
the via and part of the trench. A first anneal step is performed to remove carbon
impurities and optionally includes a H2 plasma treatment. A second ECP
process with a first deposition step at a 40 mA/cm2 current density
and second deposition step at a 60 mA/cm2 current density is used to
deposit a second copper layer-that overfills the trench. After a second anneal
step, a CMP process planarizes the copper layers. Fewer copper defects, reduced
S, Cl, and C impurities, and improved Rc performance are achieved by this method.