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/cm.sup.2 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 H.sub.2 plasma treatment. A second ECP process
with a first deposition step at a 40 mA/cm.sup.2 current density and
second deposition step at a 60 mA/cm.sup.2 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.