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Aluminum Aluminum-clad flexible circuits find use in microwave stripline33 and radiation-resistance applications. Aluminum and its alloys have good electrical conductivity, are lightweight, and can be plated, soldered, brazed, chem-milled, and anodized with good results. Laminate dielectrics include PPO,33 polyimide,34 epoxy-glass, and polyester. Precleaning for resist application includes nonetch alkaline soak, water rinsing for 5 to 10 s in chromic-sulfuric acid, rinsing, and drying. Preferred etchants include ferric chloride (12 to 18 Baum ), sodium hydroxide (5 to 10 percent), inhibited hydrochloric acid, phosphoric acid mixtures, solutions of HCl and HF, and ferric chloride hydrochloric acid mixture. Screen-printed vinyl resists and dry-film photoresist are the most durable for deep etching or chem-milling. A dip in a 10 percent nitric or chromic acid solution will remove residues from the surface or edges of conductor lines that may be left on some alloys. Dilute chromic acid has also been used for this purpose. Spray rinse thoroughly with deionized water after etching.

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Nickel and Nickel-Based Alloys Nickel is increasingly used as a metal cladding, electroplated deposit, or electroformed structure for printed wiring because of its welding properties. Nichrome- and nickel-based magnetic alloys are other examples of materials requiring special etching techniques. The methods previously described are adaptable to image transfer and etching of nickelbased materials. Etching uses ferric chloride (42 Baum ) at about 100 F. Other etchants include solutions made from one part nitric acid, one part hydrochloric acid, and three parts water, or one part nitric acid, four parts hydrochloric acid, and one part water.

Stainless Steel Alloys of stainless steel are used for resistive elements or for materials with high tensile strength. Etching of the common 300 to 400 series can be done with the following solutions:

(14.2)

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1. Ferric chloride (38 to 42 Baum ) with 3 percent HCl (optional). 2. One part HCl (37 percent) by volume, one part nitric acid (70 percent) by volume, one to three parts water by volume. Etch rate is about 0.003 in/min at 175 F, useful for high 300 to 400 series alloys. 3. Ferric chloride + nitric acid solutions. 4. One hundred parts HCl (37 percent) by weight, 6.5 parts nitric acid by weight, 100 parts water by weight.

Silver Silver, the least expensive precious metal, has excellent properties, including superior electrical and thermal conductivity, ductility, visible-light reflectivity, high melting point, and adequate chemical resistance. As such, it is widely used throughout the electronics industry. Flexible circuit structures with silver are used in electronic cameras and LED products. Standard image-transfer methods are suitable. Pre-etch cleaning should include a dip in dilute nitric acid. Mixtures of nitric and sulfuric acids are effective etchants. With silver on brass or copper substrates, a mixture of 1 part nitric acid (70 percent) and 19 parts sulfuric acid (96 percent) will dissolve the silver without attacking the substrate. The solutions should be changed frequently to prevent water absorption and the formation of immersion silver on the copper. Etching can be done with a solution containing 40 g chromic acid, 20 mL sulfuric acid (96 percent), and 2000 mL water.35 This is followed by a rinse in 25 percent ammonium hydroxide. Thin films of silver are etched in 55 percent (by weight) ferric nitrate in water or ethylene glycol. Solutions of alkaline cyanide and hydrogen peroxide will also dissolve silver. Use extreme caution. Electrolytic etching is also possible with 15 percent nitric acid at 2 V and stainless-steel cathode.

The denominator of Eq. (14.2) is third-order. For a unit-step change in R, the transform of the response is

The basic process of chemical etching to form features has been studied and modeled extensively. However, the best scientific knowledge can only proceed to an understanding of factors influencing the process. The practical execution of the process to manufacture useful circuits contains elements of experience in the best practice of several processes and choices in the selection of materials and process variations to achieve technically sound, cost-effective, and manufacturable results. In order to make fine-line circuit products, it is necessary to understand the process fundamentals so that the limitations may be understood and then overcome. The intent of this section is to briefly review the underlying science and discuss factors and practices for precision etching.

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