Refractory metals such as molybdenum (Mo) are seeing increased usage in VLSI circuit designs, primarily due to their thermal stability. Properties desirable for a VLSI metallization system with contact to silicon include high metal conductivity, good thermal stability, absence of spiking, minimal electromigration, corrosion resistance, good adhesion, and low contact resistance. It is very difficult to fulfill all of these requirements with just a single molybdenum layer. Other metals such as Cr, Ti, A1, or TiW can be used as thin underlayers to obtain the properties desired. We will describe processes for the reactive ion etching of Mo, and recent work in which chloro/fluoro gas mixtures such as CC12F2/O2, SF6/C12, and SF6/C12/ 02 have been used to etch bilayer metallization systems containing Mo, particularly Mo/TiW. In this study, the effects of different cathode cover plate materials, plasma chemistries, and other processing parameters on the etch rate, selectivities, and sidewall profiles were investigated. An analysis of plasma etch chemistry, using the results of emission spectroscopy, is presented. The methods used for the metal deposition and processing of Mo are also shown to be key factors in determining etching characteristics.Refractory metals and metal silicides have emerged as important candidates for use in the fabrication of VLSI circuits (1-7). As early as 1971, Brown et al. (8-10) described the use of Mo for fabricating self-aligned, high-speed MOSFET's. Polysilicon has a number of properties that make it useful for gate or interconnect applications, but when compared to refractory metals (Mo, W) (11), its high resistivity can limit the performance of gate-level interconnections, especially as it affects the speed of smallgeometry, densely packed circuits (12-13). Molybdenum or tungsten, on the other hand, have resistivities up to two orders of magnitude lower than that of heavily doped polysilicon.In multilevel metal structures (14, 15), the choice of materials used for the lower levels of interconnections depends not only on electrical and metallurgical requirements, but also on the ability of the metal to withstand the high temperatures that it might be subjected to in subsequent processing steps. Aluminum or aluminum alloys, traditionally used interconnect materials, have relatively poor high-temperature capabilities. They react with silicon at only a few hundred degrees (16) and can form a eutectic with Si at temperatures above 550~ that can cause complete circuit failure (17, 18). Therefore barrier layers, such as platinum silicide or titanium-tungsten alloys, must be used to limit such reactions. Furthermore, aluminum alloys preclude the use of processing temperatures above 450~ after their deposition. The long-term stability of finished devices may also be affected because of electromigration.Molybdenum, which has a melting point of 2610~ and reacts with silicon at much higher temperatures than aluminum, can remain stable during subsequent anneals, diffusions, and depositions. It can be ...