A scheme for removing foreign material from the surface of a substrate by
directing a high velocity aerosol of at least partially frozen particles
against the foreign material to be removed. Different schemes are
described for accelerating the frozen particles to very high velocities
sufficient for particle removal, removal of organic layers (e.g., hard
baked photoresist or ion implanted photoresist) and removal of metallic
layers. In one embodiment, liquid droplets are entrained in a high
velocity gas flow and the resulting gas/liquid mixture is passed through
an expansion nozzle to produce a high velocity aerosol of frozen
particles. In another embodiment, frozen aerosol particles are entrained
in, e.g., a sonic or supersonic gas jet before impacting a surface to be
cleaned. The cleaning aerosols may be applied to substrates inside a
vacuum chamber or directly from a hand-held device. Also, various scanning
systems are described for achieving substantially uniform exposure of the
substrate to the cleaning aerosol.