Chemical Milling Services for Titanium, Aluminum & Precision Alloys
MIL performs precision chemical milling to selectively remove material, refine surfaces, and meet stringent aerospace, defense, and industrial requirements—ideal for decarb removal, titanium stock reduction, weight optimization, and pre-processing for finishing operations.
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Precision Chemical Milling for Complex, High-Spec Components
Chemical milling enables controlled removal of metal from targeted areas using chemical etchants, delivering material reduction without inducing mechanical stress. It is frequently used for titanium aircraft skins, forgings, and other components requiring uniform thinning, decarb removal, or precise surface conditioning.
MIL specializes in complex masking, tight process control, and repeatable etch performance on difficult geometries and high-value parts.
Chemical Milling Highlights
- Selective and controlled material removal
- Ideal for titanium, aluminum, and ferrous alloys
- Supports weight reduction for aerospace structures
- Effective decarb / alpha-case removal
- Uniform surface finish requirements (e.g., ≤32 microinch)
- Custom masking for intricate or multi-zone etching
- Strict process control to prevent IGA, EGP, and hydrogen absorption
How the Chemical Milling Process Works
Step 1 — Surface Preparation & Masking
MIL applies specialized masking to protect areas that must not be etched.
Our masking techniques ensure:
- Precise coverage
- Sharp etch boundaries
- Reliable protection for complex or contoured parts
This step is critical for aerospace and defense components where dimensional integrity is essential.
Step 2 — Chemical Etching (Stock Removal or Decarb Removal)
Parts are immersed in a controlled chemical etchant that dissolves selected material.
Chemical milling is used for:
- Decarb / alpha-case removal on ferrous or titanium forgings
- Stock reduction on titanium sheets or contoured skins
- Surface refinement where machining is not feasible
- Etch rate, time, temperature, and chemical concentration are tightly controlled.
Step 3 — Rinsing & Neutralizing
After etching, parts undergo neutralization and rinsing to stop the chemical reaction and prevent over-etching or pitting.
Step 4 — Final Inspection & Verification
MIL verifies:
- Material removal amounts (often via witness pads)
- Surface finish quality
- Dimensional tolerance adherence
- Absence of hydrogen embrittlement, intergranular attack (IGA), or end-grain pitting
Documentation is provided for all spec-driven work.
Why Work With MIL for Chemical Milling Services?
Deep Expertise in Titanium & Aerospace Chemical Milling
Chemical milling titanium requires tight control to avoid hydrogen absorption, IGA, and dimensional distortion—areas where MIL’s process rigor provides significant risk reduction.
Complex Masking Capabilities for Precision Etching
MIL engineers custom masking solutions for difficult geometries, multi-zone etches, and fine detail work.
Predictable, Repeatable Etch Performance
Our technicians maintain strict control of chemical variables, ensuring uniform etch depths and surface quality every time.
Integrated with Multi-Step Finishing
Chemical milling often precedes:
- Anodizing
- Conversion coating
- NDT processes
- Precision cleaning
MIL performs all related services in-house for faster turnaround and reduced handling risk.
Applications & Industries Served
Component Types
- Titanium aircraft skins & structural panels
- Forgings requiring decarb/alpha-case removal
- Aerospace brackets, housings & assemblies
- Complex machined parts requiring uniform thinning
- Weight-optimized components
- Pre-treatment for coatings or adhesion-sensitive finishes
Industries
- Aerospace & defense
- Space systems
- Industrial manufacturing
- Power generation
- Medical & precision equipment
- R&D environments
Frequently Asked Questions About Chemical Milling
MIL primarily processes titanium, aluminum, and ferrous alloys, depending on specification requirements.
Chemical milling is ideal for uniform stock removal, intricate areas, and thin sections where machining would cause distortion or be cost-prohibitive.
Witness pads, dimensional checks, or thickness readings are used to confirm removal amounts.
Chemical milling typically achieves a uniform surface finish around 32 microinch or better, depending on the alloy and process conditions.
MIL tightly controls etchant chemistry, exposure time, temperature, and neutralization to avoid hydrogen absorption, IGA, and end-grain pitting—critical for titanium alloys and aerospace forgings.
Yes—MIL provides titanium stock reduction and alpha-case removal with rigorous controls tailored to aerospace specifications.
Get Started Today
Fast, accurate estimates for chemical milling and multi-step finishing workflows.
Need help confirming removal amounts or evaluating whether chemical milling is the right process? Our team can assist.
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