The Impact of Electrolytic Cell Parameters on the Boiling Rate of the Electrolyte During Electrolytic Plasma Processing

This study investigates the influence of electrolytic cell parameters on the electrolyte boiling rate during electrolytic plasma processing, a critical stage for plasma formation and subsequent surface modification. Focusing on a coaxial cell configuration with a conical anode and cylindrical cathode, this research employs analytical calculations based on the solution of the Laplace equation in spherical coordinates, validated by numerical simulations using the finite element method (Elcut 6.6), to predict electrolyte boiling times. These results are compared with experimental data, demonstrating good agreement, particularly at higher voltages (−200 V). The analysis reveals that while a simplified model provides a reasonable first approximation, it deviates at lower voltages (−50 V) due to the increasing importance of heat removal, neglected in the model construction. This discrepancy underscores the need for more sophisticated models accounting for non-uniform current distribution and heat transfer effects in complex cell geometries. The findings contribute to a deeper understanding of cathodic electrolytic plasma processing (EPP) dynamics and provide a foundation for optimizing cell design and process parameters for industrial applications such as diffusion saturation of steel components.