A typical integrated-circuit fabrication requires interconnecting millions
of microscopic transistors and resistors with metal wires. Making the
metal wires flush, or coplanar, with underlying insulation requires
digging trenches in the insulation, and then filling the trenches with
metal to form the wires. The invention provides a new "trench-less" or
"self-planarizing" method of making coplanar metal wires. Specifically,
one embodiment forms a first layer that includes silicon and germanium;
oxidizes a region of the first layer to define an oxidized region and a
non-oxidized region; and reacts aluminum or an aluminum alloy with the
non-oxidized region. The reaction substitutes, or replaces, the
non-oxidized region with aluminum to form a metallic wire coplanar with
the first layer. Another step removes germanium oxide from the oxidized
region to form a porous insulation having a very low dielectric constant,
thereby reducing capacitance.