Patent ID: 6939804

Claim:
A method of forming a composite tungsten film, comprising: introducing a substrate having at least one aperture into a process environment; providing a tungsten-containing precursor to the process environment; adsorbing the tungsten-containing precursor on the substrate; providing a reducing gas to the process environment; adsorbing the reducing gas onto the substrate, wherein a tungsten nucleation layer is formed on the substrate and within the at least one aperture; repeating the providing and adsorbing steps until the tungsten nucleation layer is formed with a desired thickness; and forming a tungsten bulk layer on the tungsten nucleation layer within the at least one aperture by a chemical vapor deposition process, comprising: maintaining the substrate within a temperature range to thermally deposit the tungsten bulk layer; exposing the substrate to a steady flow of a process gas containing a second tungsten-containing precursor, and depositing the tungsten bulk layer to fill the at least one aperture free of voids and seams.