The idea of the invention is to coat the free surface of patterned Cu
conducting lines in on-chip interconnections (BEOL) wiring by a 1-20 nm
thick metal layer prior to deposition of the interlevel dielectric. This
coating is sufficiently thin so as to obviate the need for additional
planarization by polishing, while providing protection against oxidation
and surface, or interface, diffusion of Cu which has been identified by
the inventors as the leading contributor to metal line failure by
electromigration and thermal stress voiding. Also, the metal layer
increases the adhesion strength between the Cu and dielectric so as to
further increase lifetime and facilitate process yield. The free surface
is a direct result of the CMP (chemical mechanical polishing) in a
damascene process or in a dry etching process by which Cu wiring is
patterned. It is proposed that the metal capping layer be deposited by a
selective process onto the Cu to minimize further processing. We have
used electroless metal coatings, such as CoWP, CoSnP and Pd, to
illustrate significant reliability benefits, although chemical vapor
deposition (CVD) of metals or metal forming compounds can be employed.