DC bipolar anodization of aluminum: Wider anode area than expected on the bipolar electrodes

In this study, the electrical potential distributions on aluminum bipolar electrodes (BPEs) subjected to bipolar anodization in a direct current (DC) electric field were investigated. Aluminum sheets were used as BPEs, suspended in an electrolyte solution, and positioned either vertically or horizontally at the center of a cell. The results of reflective interference measurements, depth-profiling analysis, and re-anodization clearly revealed that the thicknesses of the porous alumina films and barrier layers near the aluminum substrates can be taken to represent the potential distributions on the horizontally located BPEs; the thickest anodic alumina was formed at the edge of the anodic pole of the BPE, and its thickness continuously decreased in the direction of the cathodic pole. Furthermore, the area of the anodic reaction was much larger than expected, accounting for 90% of the BPE.