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How to remove steel machine screws tapped into aluminum

8-32nf machine screws were used to tap a hole in an aluminum decorative front and left in place. I now have to remove the steel machine screws, but the aluminum fillings from the tapping are becoming trapped in the threads of the steel machine screws, are jamming, and causing the machine screws to break off in the aluminum. Is there any way that anyone knows of to remove these machine screws without breaking them?

Mike Tinker

2006

2006

Maybe dissolving them with nitric acid. It will attack steel but not aluminum. Confine the acid making a pool with putty to avoid run-off. Use rubber gloves [on eBay or Amazon], goggles [on eBay or Amazon], the minimum amount of acid and be careful. Disposal may require neutralization with an alkaline and further advise depending on volume.

Guillermo Marrufo

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