Aluminum Alloys FeCl₃+HCl

Chemical Etching Formula
Al1060 with FeCl₃+HCl

Working with Al1060 on a chemical etch line begins with the right formula. The FeCl₃+HCl system documented below produces through etch (double-sided) across 0.05-0.5 mm sheet, with a minimum hole-diameter range of 60-600 μm and a minimum line-width range of 100-500 μm. The numbers scale with thickness — thinner stock yields finer features.

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
30 °Bé Concentration
1.250 Specific Gravity
38 °C Bath Temperature
Through etch (double-sided) Etch Depth Type
0.05-0.5 mm Thickness Range
0.20 mm Typical Thickness
0.12-2.9 m/min Conveyor Speed Range
0.42 m/min Typical Speed
60-600 μm Min Hole Ø Range
100-500 μm Min Line Width Range
10-96 μm Undercut Range
2.60 Etch Factor (EF)
97.5% Typical Yield (96.8-97.9%)

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 38°C, concentration 30 °Bé, specific gravity 1.250. The recipe is tuned for through etch (double-sided). Conveyor speed is the primary throughput control, ranging 0.12-2.9 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

When laying out artwork for Al1060 at through etch (double-sided), plan for a minimum hole diameter in the 60-600 μm range and a minimum line width in the 100-500 μm range, depending on the chosen sheet thickness within 0.05-0.5 mm. The etch factor of ~2.60 and undercut range of 10-96 μm determine how much the mask must be biased to land the finished dimension on target.

Design Rule Summary
• Minimum hole diameter range: 60-600 μm
• Minimum line width range: 100-500 μm
• Single-side undercut range: 10-96 μm
• Typical etch factor (EF): 2.60

Yield & Production Economics

This formula delivers a typical yield of 97.5% (range 96.8-97.9%). At that rate, per-part economics are driven mostly by fixed photomask and setup cost for small batches and by sheet utilisation for large runs. The chemistry itself does not change with quantity, so the same recipe serves prototype and production volumes.

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

Yes. Wet chemical etching is a non-contact chemical process with no mechanical cutting or thermal input, so etched Al1060 features are completely free of burrs, work-hardening, and heat-affected zones. That edge quality is the defining advantage over stamping or laser cutting for precision flat parts.

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.

Request a Quote Browse Formulas