Optimization of electrolytic plasma polishing process and surface performance analysis for 6061 aluminum alloy

Electrolytic Plasma Polishing (EPP), an innovative technology for polishing, has been utilized to improve the surface performance of 6061 aluminum alloys. An orthogonal experimental approach was carried out to investigate the multiple factors influencing the surface quality of aluminum alloys during the polishing process. The results indicated that peaks and scratches on the surface were successfully removed after polishing, with the average roughness reduced to 0.138 μm, approximately 1/8 of the original roughness. Additionally, the EPP process enhanced the substrate's corrosion resistance and hydrophobicity. Finally, it is proposed that the mechanism of surface smoothing effect of EPP is attributed to the combined action of plasma chemical dissolution and cavitation forces peeling. This research indicates EPP as a promising finishing technique with considerable potential for enhancing the surface performance of aluminum alloys in electronic component applications. • EPP technique polished 6061 aluminum alloy to high-quality surfaces. • Factors for surface roughness ranked: time > voltage > temperature > depth. • EPP reduced surface roughness and enhanced corrosion resistance and hydrophobicity. • EPP smooths surfaces via plasma dissolution and cavitation peeling effects.