A method employing atomic layer deposition rapid vapor deposition (RVD)
conformally deposits a dielectric material on small features of a
substrate surface. The resulting dielectric film is then annealed using a
high density plasma (HDP) at a temperature under 500.degree. C. in an
oxidizing environment. The method includes the following three principal
operations: exposing a substrate surface to an aluminum-containing
precursor gas to form a substantially saturated layer of
aluminum-containing precursor on the substrate surface; exposing the
substrate surface to a silicon-containing precursor gas to form the
dielectric film; and annealing the dielectric film in a low temperature
oxygen-containing high density plasma. The resulting film has improved
mechanical properties, including minimized seams, improved WERR, and low
intrinsic stress, comparable to a high temperature annealing process
(.about.800.degree. C.), but without exceeding the thermal budget
limitations of advanced devices.