Aluminum Alloys FeCl₃+HCl

Chemical Etching Formula
Al3105 with FeCl₃+HCl

The FeCl₃+HCl chemistry is a proven formula for Al3105. This reference sheet lists the concentration (32 °Bé), specific gravity (1.270), bath temperature (40°C), and the full range of conveyor speeds and feature tolerances that result. Use it to size your process before committing to a production trial.

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
32 °Bé Concentration
1.270 Specific Gravity
40 °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
10-97 μm Undercut Range
2.57 Etch Factor (EF)
97.5% Typical Yield (96.8-97.9%)

Why FeCl₃+HCl for Al3105?

On Al3105, 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 Al3105 etch line runs a variant of this formula.

Process Window & Bath Control

Hold the bath at 40°C with concentration 32 °Bé (specific gravity 1.270). Across the 0.05-0.5 mm thickness range, conveyor speed runs from 0.12-2.9 m/min — thinner sheets move faster, thicker sheets slower, in roughly inverse proportion to thickness. A typical mid-range setpoint is 0.42 m/min for 0.20 mm stock. Use redundant PID temperature control to hold the bath within ±1.5°C, and titrate at least once per shift.

Design Rules & Tolerances

Design rules for this recipe: hole diameter 60-600 μm, line width 100-500 μm, single-side undercut 10-97 μm — all as a function of thickness across 0.05-0.5 mm. The higher the etch factor (this formula holds about 2.57), the tighter the achievable tolerance. Below the minimum feature sizes, yield falls off steeply, so treat those numbers as hard floors rather than targets.

Design Rule Summary
• Minimum hole diameter range: 60-600 μm
• Minimum line width range: 100-500 μm
• Single-side undercut range: 10-97 μm
• Typical etch factor (EF): 2.57

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 Al3105 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) 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)

Frequently Asked Questions

Minimum producible hole diameter ranges 60-600 μm across the 0.05-0.5 mm thickness band, following the 1.2× material-thickness design rule. The smallest holes are only available on the thinnest stock; attempting holes below the floor for a given thickness causes yield to drop sharply.

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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