Modified multilayered metal line structure for use with tungsten-filled vias in integrated circuit structures

An improved integrated circuit structure comprising a composite metal interconnect structure with an aluminum-containing metal core layer, and with direct electrical and metallurgical connection between a tungsten layer in the composite metal interconnect structure and a tungsten filler material in an overlying via which comprises:

• a) an integrated circuit structure formed on a semiconductor substrate;
• b) a first layer of dielectric material formed over said integrated circuit structure;
• c) a first protective barrier layer comprising a TiN-containing electrically conductive material formed on an upper surface of said first layer of dielectric material;
• d) an aluminum-containing core layer formed on said first protective barriers layer, whereby said first protective barrier layer inhibits interaction between said first dielectric layer and said aluminum layer;
• e) a second protective barrier layer comprising a TiN-containing electrically conductive material formed on the upper surface of said aluminum-containing core layer to inhibit interaction between said aluminum-containing core layer and materials formed over said aluminum-containing core layer;
• f) a layer of tungsten formed on the upper surface of said second protective barrier layer capable of functioning as an etch stop layer for vias subsequently formed in an overlying dielectric layer, said second protective barrier layer inhibiting interaction between said aluminum-containing core layer and said tungsten layer;
• g) a third protective barrier layer comprising a TiN-containing electrically conductive material formed on an upper surface of said tungsten layer and capable of functioning as an antireflective coating (ARC), whereby said first, second, and third protective barrier layers of TiN-containing electrically conductive material, said aluminum-containing core layer, and said tungsten layer comprise said composite metal interconnect structure, with said first, second, and third protective barrier layers protecting said aluminum-containing layer and said tungsten layer from interaction with one another or with other adjacent materials;
• h) a second dielectric layer formed over said third protective barrier layer;
• i) one or more vias formed in said second dielectric layer, and extending through said second dielectric layer and through said third protective barrier layer down into said tungsten layer;
• j) a layer of TiN formed on the sidewalls of said vias to promote adhesion of tungsten via filler material with the sidewalls of said one or more vias;
• and
• k) electrically conductive tungsten filler material in said one or more vias and metallurgically and electrically connected with said tungsten layer of said composite metal interconnect structure through the unlined bottom of said one or more vias;
• to thereby provide a low resistance electrical connection between said tungsten-filled one or more vias and said aluminum-containing core layer of said composite metal interconnect structure.