Etching Anode Foil with Branch Tunnels for Aluminum Electrolytic Capacitors

Al foil for high-voltage aluminum electrolytic capacitor was first D.C. etched in HCl–H2SO4 mixed acidic solution to form main tunnels and then D.C. etched in natural NaCl solution containing 0.1% H2C2O4 and different trace amounts of Zn(NO3)2. Between the two etching processes, Zn nuclei were deposited on the interior surface of the main tunnels by the natural occluded corrosion cell effect to form micro Zn–Al galvanic local cells. The effects of Zn nuclei on the cross-section etching and electrochemical behavior of Al foil were investigated using scanning electron microscopy, polarization curve measurement, and electrochemical impedance spectroscopy. The sub-branch tunnels can form along the main tunnels owing to the formation of Zn–Al micro-batteries, in which Zn is the cathode and Al is the anode. Increasing Zn(NO3)2 concentration increases the number of Zn nuclei that can serve as sites for branch tunnel initiation along the main tunnels, thereby enhancing the specific capacitance of etched Al foil.