ABSTRACT
A chemical metal removal process known as chemical milling is commonly used by the aerospace industry for selectively removing metal to reduce weight and produce parts of varying gage. It is particularly benecial on structure where the removal of small amounts of metal over large surface areas is desired, or where the part geometry causes difcult access for cutting tools. It can be used on all metal forms including sheet metal, plate, forging, and extrusion products in manufacturing aircraft components. The chemical machining process was developed based on the principles of chemical reaction between metals and chemical reagents or etchants like acids or alkaline solutions. Chemical milling is the oldest of the nontraditional machining processes and has been used for many years in the aerospace industry. Advances in high-speed mechanical milling are gradually reducing the usage of chemical milling in aerospace industries.
