I need to use electropolishing instead of grinding for layer removal with a rate of 40-60 um/h. Material is Aluminum alloy 6xxx series. What would be the best choice of electrolyte composition, temperature, voltage, current, cathode ? There is a wide range of selection for electrolyte compositions, but recommendations are done generally for surface quality ennhancement, not for the layer removal process.
Depending on your objectives, electrolyte and conditions may change. However, for an homogeneous electropolish and good surface conditions, you can use the same protocol used in TEM sample preparation. The following conditions are given as :
--> Solution : 30% HNO3 in pure methanol
--> Tension : 17 V
--> Temperature : -20°C
This conditions allows to remove at a very high rate. Therefore you could lower the temperature or the tension to achieve the desired removal rate.
Electrolytes (Mixed solution with the volume ratio of perchloric acid to ethanol as 1:8) at 2 V and 27 °C. Also, ultrasonic agitation is preferable.
Please check the following attached research article for your reference.
Article Electropolishing of high-purity aluminium in perchloric acid...
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