A method of forming an interconnect structure comprising: forming a sacrificial inter-
metal dielectric (IMD) layer over a substrate, wherein the sacrificial IMD layer comprising a carbon-based film, such as
amorphous carbon, advanced patterning films,
porous carbon, or any combination thereof; forming a plurality of
metal interconnect lines within the sacrificial IMD layer; removing the sacrificial IMD layer, with an
oxygen based reactive process; and depositing a non-conformal
dielectric layer to form air gaps between the plurality of
metal interconnect lines. The
metal interconnect lines may comprise
copper, aluminum,
tantalum,
tungsten,
titanium,
tantalum nitride,
titanium nitride,
tungsten nitride, or any combination thereof. Carbon-based films and patterned
photoresist layers may be simultaneously removed with the same reactive process. Highly reactive
hydrogen radicals processes may be used to remove the carbon-based film and simultaneously pre-clean the
metal interconnect lines prior to the deposition of a conformal metal barrier liner.