FOCUS ON MATERIALS
An etched Inconel plate.
Precision Micro’ s new etch room facility.
This problem is not unique to Inconel. Some of the most notoriously difficult materials to machine are high-performance alloys such as Inconel itself, Haynes 188, titanium alloys and tungsten carbide.
These materials are all valued for their exceptional strength, high-temperature resistance and ability to maintain their properties under stress. However, that same resilience makes them incredibly stubborn when it comes to cutting or shaping with conventional methods.
The challenge becomes even greater when dealing with thin-gauge parts or intricate geometries. Traditional machining methods can introduce stress to the component, as well as distortion or surface defects, compromising its integrity or performance. This is especially problematic in energy systems where safety, flow efficiency and material reliability are directly linked to performance outcomes— and regulatory compliance.
For instance, in hydrogen fuel cell stacks, any defect or distortion in a flow plate can disrupt hydrogen distribution and reduce cell efficiency. In more severe cases, it can even lead to catastrophic system failure.
Making the choice
This is why alternative manufacturing methods such as photochemical machining( PCM), known as chemical etching, are gaining ground. Unlike conventional machining, etching is a non-contact, ambient-temperature process that selectively removes metal using acidbased chemistries.
When tailored to suit high-performance alloys such as Inconel, etching can produce intricate components with tight tolerances and clean edges, all without inducing mechanical stress or altering the material’ s properties.
Because it doesn’ t rely on hard tooling or heat-intensive processes, chemical etching is especially effective for high-precision, thingauge parts such as those found in compact heat exchangers, hydrogen reformers or fuel cell plates in advanced power systems.
It’ s a great example of how the right manufacturing approach can turn a tricky material, like Inconel, into a real advantage. In modern engineering, Inconel isn’ t just known for handling extremes, it is also a reminder that sometimes the toughest materials can lead to the most advanced and reliable solutions— if you choose the right approach. n
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Material versatility
Chemical etching demonstrates strong compatibility with a diverse array of metals, including corrosion-resistant stainless steel, conductive copper and various nickel alloys. The process effectively overcomes the limitations encountered when working with materials that possess hard, soft or brittle properties.
About Precision Micro
Precision Micro is a global specialist in chemical etching. Headquartered in Birmingham( UK) since 1962, the company manufactures millions of precision-etched components for hightech industries including automotive, aerospace, medical and energy. Its 44,000ft ²( 4,100m ²) facility houses what it calls“ the largest dedicated sheet metal etching capacity in the world, with the ability to process more than 2,000 material variants.” It is one of the largest photochemical machining suppliers globally.
Below and right: Etch tooling.
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