Automated Electrophoretic Deposition Module Design and Ca-Coated A7075 Corrosion Study

This study investigates the installation and operation of an automated electrophoretic deposition (EPD) unit for applying Ca coatings on aluminum alloy parts, with a focus on optimizing electrode distance and deposition parameters. The dynamic adjustment of the anode–cathode distance during the process was crucial in influencing the uniformity and adhesion of the Ca coating. The electrolyte solution consisted of 50% acetone, 50% distilled water and 5[Formula: see text]g/500[Formula: see text]ml of pure Ca. The average thickness of the Ca coating was approximately 180 microns. Immersion corrosion tests revealed that after a 48[Formula: see text]h period, the coated sample lost 0.5[Formula: see text]g of weight, while the uncoated sample lost 1.1[Formula: see text]g. These findings demonstrate that the thickness and uniformity of the Ca coating significantly influence its protective properties. In conclusion, this study provides valuable insights into the optimization of EPD parameters and the role of Ca coatings in enhancing corrosion resistance in industrial applications.