Precision Alloys FeCl₃+HCl

Chemical Etching Formula
1J46 Permalloy with FeCl₃+HCl

For engineers selecting an etching chemistry for 1J46 Permalloy, the FeCl₃+HCl formula shown here defines the bath composition, temperature window, and achievable feature sizes across a 0.05-0.3 mm thickness band. Typical mass-production yield for this recipe is 96.6%, with a typical conveyor speed of 0.67 m/min at 50°C.

Formula Summary

The table below summarizes every parameter that defines this etching formula. Values listed as ranges scale with sheet thickness across the supported band.

FeCl₃+HCl Etchant System
44 °Bé Concentration
1.410 Specific Gravity
50 °C Bath Temperature
Through etch (double-sided) Etch Depth Type
0.05-0.3 mm Thickness Range
0.15 mm Typical Thickness
0.19-2.77 m/min Conveyor Speed Range
0.67 m/min Typical Speed
60-360 μm Min Hole Ø Range
100-300 μm Min Line Width Range
9-55 μm Undercut Range
2.73 Etch Factor (EF)
96.6% Typical Yield (96.1-96.8%)

Why FeCl₃+HCl for 1J46 Permalloy?

Ferric-chloride-based formulas are the industrial workhorse for ferrous, nickel, and copper-bearing alloys like 1J46 Permalloy. The Fe³⁺ ion oxidizes the metal surface; where HCl is present it regenerates dissolved species and stabilizes chloride concentration. The result on 1J46 Permalloy is anisotropic etching with predictable undercut and an easily regenerated spent bath.

Process Window & Bath Control

Bath control for 1J46 Permalloy in FeCl₃+HCl: temperature 50°C, concentration 44 °Bé, specific gravity 1.410. The recipe is tuned for through etch (double-sided). Conveyor speed is the primary throughput control, ranging 0.19-2.77 m/min across the supported thickness range. Check specific gravity each shift with a calibrated hydrometer and correct with fresh make-up or water as needed.

Design Rules & Tolerances

Feature sizes scale with sheet thickness. For this formula the minimum hole diameter ranges 60-360 μm and the minimum line width ranges 100-300 μm across the 0.05-0.3 mm band, following the industry 1.2× (hole) and 1.0× (line) thickness rules. Single-side undercut ranges 9-55 μm, and the etch factor is about 2.73. Size your photomask by subtracting twice the expected undercut from each finished feature dimension.

Design Rule Summary
• Minimum hole diameter range: 60-360 μm
• Minimum line width range: 100-300 μm
• Single-side undercut range: 9-55 μm
• Typical etch factor (EF): 2.73

Yield & Production Economics

Expect a yield in the 96.1-96.8% range for 1J46 Permalloy with FeCl₃+HCl, with 96.6% typical on a well-controlled line. Most rejects trace back to upstream coating and exposure rather than to the etch bath itself, so tightening photolithography control is usually the fastest path to a higher number.

Typical Applications

Parts produced with the FeCl₃+HCl formula on 1J46 Permalloy are common in hermetic sealing rings, lead frames matched to glass/ceramic, and magnetic shielding. The burr-free, stress-free nature of chemical etching makes it the preferred process wherever flatness and edge quality matter more than raw throughput.

More Precision Alloys Formulas

Other formulas in the same material family.

1J22 Iron-Cobalt Alloy FeCl₃+HCl Through etch (double-sided) 1J50 Permalloy FeCl₃+HCl Through etch (double-sided) 1J79 Permalloy FeCl₃+HCl Through etch (double-sided) 1J85 Super-Permalloy FeCl₃+HCl Through etch (double-sided) HyMu80 (Permalloy) FeCl₃+HCl Through etch (double-sided) Invar36 alloy FeCl₃+HCl Through etch (double-sided)

Frequently Asked Questions

The typical etch factor for this recipe is 2.73 — vertical etch depth is about 2.73× the single-side undercut. Higher EF means tighter feature tolerance; values near or above 3.0 are close to best-in-class for wet etching, and 1J46 Permalloy in FeCl₃+HCl sits in the typical production range.

Need a Quote for This Process?

WET Etched runs production wet chemical etching lines using the FeCl₃+HCl chemistry. Send us your part drawing and quantity for a full process quote.

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