Aluminum Alloys FeCl₃+HCl

Chemical Etching Formula
Al6082 with FeCl₃+HCl

The FeCl₃+HCl chemistry is a proven formula for Al6082. This reference sheet lists the concentration (34 °Bé), specific gravity (1.290), bath temperature (43°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
34 °Bé Concentration
1.290 Specific Gravity
43 °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
10-100 μm Undercut Range
2.50 Etch Factor (EF)
97.5% Typical Yield (96.8-97.9%)

Why FeCl₃+HCl for Al6082?

Ferric-chloride-based formulas are the industrial workhorse for ferrous, nickel, and copper-bearing alloys like Al6082. The Fe³⁺ ion oxidizes the metal surface; where HCl is present it regenerates dissolved species and stabilizes chloride concentration. The result on Al6082 is anisotropic etching with predictable undercut and an easily regenerated spent bath.

Process Window & Bath Control

The process window for this FeCl₃+HCl formula centres on 43°C and 34 °Bé. Conveyor speed spans 0.12-2.9 m/min over the 0.05-0.5 mm thickness band; the typical operating point is 0.42 m/min. Every 5°C drop in bath temperature requires roughly a 30% reduction in conveyor speed to hold the same etch depth, so temperature stability is the single biggest lever on consistency.

Design Rules & Tolerances

Feature sizes scale with sheet thickness. For this formula the minimum hole diameter ranges 60-600 μm and the minimum line width ranges 100-500 μm across the 0.05-0.5 mm band, following the industry 1.2× (hole) and 1.0× (line) thickness rules. Single-side undercut ranges 10-100 μm, and the etch factor is about 2.50. Size your photomask by subtracting twice the expected undercut from each finished feature dimension.

Design Rule Summary
• Minimum hole diameter range: 60-600 μm
• Minimum line width range: 100-500 μm
• Single-side undercut range: 10-100 μm
• Typical etch factor (EF): 2.50

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

Parts produced with the FeCl₃+HCl formula on Al6082 are common in lightweight RF shields, heat-spreader masks, nameplates, decorative trim, and lightweight structural lattices. 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 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

Run the bath at 43°C. Holding much above 48°C can degrade photoresist adhesion and erode feature edges; running below 38°C slows the etch and forces a conveyor-speed reduction. Production lines hold 43°C within ±1.5°C using redundant PID control.

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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