Aluminum Alloys FeCl₃+HCl

Chemical Etching Formula
Al5005 with FeCl₃+HCl

Working with Al5005 on a chemical etch line begins with the right formula. The FeCl₃+HCl system documented below produces through etch (double-sided) across 0.1-0.5 mm sheet, with a minimum hole-diameter range of 120-600 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
32 °Bé Concentration
1.270 Specific Gravity
40 °C Bath Temperature
Through etch (double-sided) Etch Depth Type
0.1-0.5 mm Thickness Range
0.25 mm Typical Thickness
0.12-1.08 m/min Conveyor Speed Range
0.32 m/min Typical Speed
120-600 μm Min Hole Ø Range
100-500 μm Min Line Width Range
20-98 μm Undercut Range
2.55 Etch Factor (EF)
97.2% Typical Yield (96.5-97.5%)

Why FeCl₃+HCl for Al5005?

Ferric-chloride-based formulas are the industrial workhorse for ferrous, nickel, and copper-bearing alloys like Al5005. The Fe³⁺ ion oxidizes the metal surface; where HCl is present it regenerates dissolved species and stabilizes chloride concentration. The result on Al5005 is anisotropic etching with predictable undercut and an easily regenerated spent bath.

Process Window & Bath Control

Bath control for Al5005 in FeCl₃+HCl: temperature 40°C, concentration 32 °Bé, specific gravity 1.270. The recipe is tuned for through etch (double-sided). Conveyor speed is the primary throughput control, ranging 0.12-1.08 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 120-600 μm and the minimum line width ranges 100-500 μm across the 0.1-0.5 mm band, following the industry 1.2× (hole) and 1.0× (line) thickness rules. Single-side undercut ranges 20-98 μm, and the etch factor is about 2.55. Size your photomask by subtracting twice the expected undercut from each finished feature dimension.

Design Rule Summary
• Minimum hole diameter range: 120-600 μm
• Minimum line width range: 100-500 μm
• Single-side undercut range: 20-98 μm
• Typical etch factor (EF): 2.55

Yield & Production Economics

Expect a yield in the 96.5-97.5% range for Al5005 with FeCl₃+HCl, with 97.2% 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

Al5005 etched with this recipe typically ends up in lightweight RF shields, heat-spreader masks, nameplates, decorative trim, and lightweight structural lattices. Because chemical etching applies no mechanical or thermal load, the finished features are free of work-hardening and heat-affected zones — a decisive advantage over stamping or laser cutting for these uses.

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

This formula is documented for a sheet-thickness range of 0.1-0.5 mm, with a typical value of 0.25 mm. Outside this band the same chemistry may still work, but conveyor speed and feature tolerances should be re-verified with a sample run before production.

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