Seattle - Chemical milling
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Chemical milling in manufactures is also known as etching. It is a process that uses bases, acids or other chemicals to dissolve unwanted materials such as semiconductor materials, glass or metal.
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This process is used on a wide variety of distinct metals, and the removal of depths as large as 0.5 inch or 12 mm are achieved. It has applications in the semiconductor fabrication and printed circuit board industries, and is also employed in the aerospace industry, to remove thin layers of metal/materials from large aircraft components, such as extruded parts and missile skin panels.
There are distinct types of chemical milling. One is wet etching and another is photochemical etching. distinct materials want distinct types of etchants, for instance, sodium hydroxide is used for aluminum, and ferric chloride or ammonia or ammonium persulphate is used for copper. It is widely used to develop integrated circuits, and the semiconductor manufactures uses plasma etching.
Another type is photo chemical milling. This is a process that produces 2D shapes and parts by creating a chemical resist mask on the face of the sheet metal, and then chemically dissolving material from the unmasked areas.
Photo chemical milling processes are as follows :
o A photo unyielding coating applied to make the metal sensitive to light
o A photo mask is placed over the sensitized sheet metal
o The sheet of metal is exposed to ultraviolet light
o The photo resist is industrialized into the masked pattern
o The sheet is etched to remove the exposed metal areas leaving the final part
o The part is then cleaned
This type can offer high precision and detailed shapes in thin metal sheets, and the process is particularly competitive for complex shapes and parts.
It can make roughly any 2D shape in thin gauge sheet metal. Applications can contain :
o Electrical shields
o optical interrupters
o Eraser shields
o Gaskets
o Shims
Electro chemical milling is a method of removing metal by electrochemical processes, and is regularly used in mass production of very hard materials. Electro chemical milling can cut odd or small shapes in very hard steels such as carbide, kovar, inconel and titanium, and is also widely used as an effective deburring process.
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