Interconnect structures possessing a non-porous (dense) low-k
organosilicate glass (OSG) film utilizing a porous low-k OSG film as an
etch stop layer or a porous low-k OSG film using a non-porous OSG film as
a hardmask for use in semiconductor devices are provided herein. The
novel interconnect structures are capable of delivering improved device
performance, functionality and reliability owing to the reduced effective
dielectric constant of the stack compared with that of those
conventionally employed and also because of the relatively uniform line
heights made feasible by these unique and seemingly counterintuitive
features. The present invention also provides a fluorocarbon-based dual
damascene etch process that achieves selective etching of a dense low-k
OSG films relative to that of a porous low-k OSG film owing to the
tunability of the gas-phase fluorine:carbon ratio (gas dissociation) and
ion current below a critical threshold and given the larger carbon
content of the porous film relative to that of the dense film.