Aluminum Alloys FeCl₃+HCl

Chemical Etching Formula
Al1060 with FeCl₃+HCl

This page documents the reference wet chemical etching formula for Al1060 using the FeCl₃+HCl system. The recipe below covers a sheet-thickness range of 0.01-0.02 mm and is configured for through etch (double-sided). Every value is drawn from operational process records rather than theoretical calculation, and is provided as a starting point for your own process development.

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
28 °Bé Concentration
1.220 Specific Gravity
36 °C Bath Temperature
Through etch (double-sided) Etch Depth Type
0.01-0.02 mm Thickness Range
0.01 mm Typical Thickness
16.37-59.06 m/min Conveyor Speed Range
28.89 m/min Typical Speed
46252 μm Min Hole Ø Range
100 μm Min Line Width Range
46025 μm Undercut Range
2.62 Etch Factor (EF)
98.8% Typical Yield (98.8%)

Why FeCl₃+HCl for Al1060?

On Al1060, the ferric chloride system attacks the alloy's oxide layer continuously while ferric ions drive dissolution. It is regenerable, compatible with standard photolithography, and produces clean burr-free edges — which is why nearly every Al1060 etch line runs a variant of this formula.

Process Window & Bath Control

Bath control for Al1060 in FeCl₃+HCl: temperature 36°C, concentration 28 °Bé, specific gravity 1.220. The recipe is tuned for through etch (double-sided). Conveyor speed is the primary throughput control, ranging 16.37-59.06 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 46252 μm and the minimum line width ranges 100 μm across the 0.01-0.02 mm band, following the industry 1.2× (hole) and 1.0× (line) thickness rules. Single-side undercut ranges 46025 μm, and the etch factor is about 2.62. Size your photomask by subtracting twice the expected undercut from each finished feature dimension.

Design Rule Summary
• Minimum hole diameter range: 46252 μm
• Minimum line width range: 100 μm
• Single-side undercut range: 46025 μm
• Typical etch factor (EF): 2.62

Yield & Production Economics

Expect a yield in the 98.8% range for Al1060 with FeCl₃+HCl, with 98.8% 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

Typical applications for Al1060 processed with FeCl₃+HCl include lightweight RF shields, heat-spreader masks, nameplates, decorative trim, and lightweight structural lattices. The formula's tolerance band and yield make it well suited to medium-to-high-volume precision flat parts.

More Aluminum Alloys Formulas

Other formulas in the same material family.

Al1060 FeCl₃+HCl Through etch (double-sided) Al1100 FeCl₃+HCl Through etch (double-sided) Al2014 FeCl₃+HCl Through etch (double-sided) Al2017 FeCl₃+HCl Through etch (double-sided) Al2024 FeCl₃+HCl Through etch (double-sided) Al3003 FeCl₃+HCl Through etch (double-sided)

Frequently Asked Questions

Standard pre-treatment is degrease, micro-etch to activate the surface, rinse, photoresist lamination or coating, UV exposure through the artwork, and develop. Pre-treatment quality directly drives yield for Al1060: poor degreasing causes resist adhesion failures that show up as random pinhole defects in the etched pattern.

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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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