We present a method that utilizes surface topography to control the di
stribution of grain sizes, single grain segment lengths and polygrain
cluster lengths in AI-Cu thin films. Microstructural data for the grai
n size and segment/cluster length distribution parameters are presente
d that demonstrate the influence of various topographical features adj
acent to conductor lines. Experimental results show the impact of thes
e features on electromigration failure times. Our results demonstrate
that the relationship between median failure time and segment length i
s consistent with the critical threshold length concept for long inter
connects containing large numbers of single grain segments and polygra
in clusters. These results demonstrate the importance of the segment l
ength and type in controlling electromigration mass transport.