In damascene process integration, a reducing plasma is applied after the
etch stop or barrier layer is opened over a copper layer. Currently known
methods for opening barrier layers suffer from the disadvantage that they
cause at least some of the underlying copper to oxidize to copper oxide.
Because copper oxide is selectively removed by subsequent wet cleaning,
voids can form where damaged copper (e.g., copper oxide) is removed, thus
compromising the reliability of metal-to-metal contact in vias. The
present invention advantageously overcomes this and other disadvantages
of the prior art through the use of a hydrogen plasma following the
barrier layer opening step, which repairs damaged copper (e.g., reduces
copper oxide to copper), thus preventing and/or diminishing defects in
metal-to-metal contacts in vias and concomitantly improving the
reliability of the same.