Patent ID: 6977217

Claim:
A method of filling a via structure, the method comprising: depositing a liner in a via; depositing a barrier layer in the via, the barrier layer comprising a material that does not substantially react with aluminum, wherein the liner and the barrier layer are deposited by ionized metal plasma (IMP) physical vapor deposition (PVD); depositing aluminum over the barrier layer in the via using a hot aluminum process, the hot aluminum process comprising a first PVD step at about room temperature followed by a second PVD step at a temperature higher than room temperature, the aluminum in the via being electrically coupled to an underlying metal stack comprising a titanium layer, an aluminum layer over the titanium layer, and a titanium tungsten layer over the aluminum layer; wherein the liner, the barrier layer, and the aluminum in the via are deposited in-situ in a same device fabrication system.