FOCUS ON MATERIALS
The etching process. Chemical etching.
SELECTING TO ETCH
When tailored to suit high-performance alloys such as Inconel, etching can produce intricate components with tight tolerances and clean edges without inducing mechanical stress or altering the material’ s properties.
“ Unlike conventional machining, photochemical machining( PCM) or chemical etching is a non-contact, ambient-temperature process that selectively removes metal using acid-based chemistries.”
In engineering, the materials that are hardest to work with are often the ones that you want most in your design— and Inconel is no exception. However, Inconel’ s greatest strengths can also be its biggest challenges, particularly when it comes to shaping and machining it into functional components.
Inconel is a family of nickel-chromium superalloys that you’ ll often hear in conversations about extreme engineering environments. Thanks to its ability to withstand high temperatures, corrosion and pressure, the material is suitable for demanding applications.
This is particularly the case in the energy sector where thermal efficiency, chemical resilience and long-term material stability are non-negotiable. Whether it’ s for hydrogen, for example, Inconel is relied upon to keep systems running safely under intense operational loads.
Performance under pressure
So, what exactly makes Inconel so special, but so difficult to work with? Well, Inconel is all about performance under pressure. Variants such as Inconel 600, 625, 718 and X-750 are engineered to maintain their strength and structural integrity in conditions that would overwhelm most metals.
Whether it’ s exposure to high temperatures, aggressive chemicals or both, Inconel resists corrosion and creep with great efficiency. This makes it ideal for components used in heat exchanger plates and fuel cell hardware— quite simply, anywhere where reliability is critical and failure isn’ t an option.
In the energy sector specifically, this includes roles in hydrogen electrolysers, nuclear fuel assemblies and high-pressure thermal systems that demand precision and zero margin for error.
The associated challenges
Of course, performance comes at a cost, especially during the manufacturing process. The very qualities that make Inconel such a valuable material also make it extremely difficult to machine.
It work-hardens rapidly, meaning it becomes tougher the more you try to cut it. This increases tool wear, slows production and drives up costs. It also retains heat, which can lead to excessive temperatures during machining, further damaging tools and risking dimensional inaccuracies.
By
Ben Kitson,
Head of Business Development, Precision Micro
About the author
Ben Kitson is head of business development at chemical etching specialist, Precision Micro. He is a creative and strategic manager with over 20 years of experience in direct major customer relationship development and maximisation of the profit line. This includes nurturing current business, identifying prospective opportunities and project managing challenging situations. He boasts a strong aerospace background in contract negotiations with companies such as Rolls Royce; Goodrich; Meggitt; Umeco; Turbomeca and Eaton.
94 | ismr. net | ISMR September 2025