Volume 6 Preprint 59


Effect of SO42-, S2O32- and HSO4- Ion Additives on Electrochemical Etching of Pure Aluminium Foil for Aluminium Electrolytic Capacitor

S.-I. Pyun and K.-H. Na

Keywords: aluminium, sulphate, thiosulphate, hydrogen sulphate, capacitor

Abstract:

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Volume 6 Paper C145 Effect of SO42-, S2O32- and HSO4- Ion Additives on Electrochemical Etching of Pure Aluminium Foil for Aluminium Electrolytic Capacitor S.-I. Pyun and K.-H. Na Dept. Mat. Sci. & Eng., KAIST, 373-1, Guseong-dong, Yuseong-gu, Daejeon, 305-701, Republic of Korea, sipyun@webmail.kaist.ac.kr Abstract The effects of sulphate (SO42-), thiosulphate(S2O32-) and hydrogen sulphate (HSO4-) ion additives on etching of pure aluminium (Al) foil for Al electrolytic capacitor have been investigated in 4 M sodium chloride (NaCl) solution as a function of anion concentration using potentiodynamic polarisation experiment, galvanostatic potential transient technique, electrochemical impedance spectroscopy and scanning electron microscopy. From the potentiodynamic polarisation curves and galvanostatic potential transients, it was observed that pit and etch tunnel initiation was inhibited by the addition of SO42- and S2O32- ions. In contrast, in the presence of HSO4- ions pit and etch tunnel initiation was enhanced. While galvanostatic potential transients resulting just after short current interruption in the presence of SO42and S2O32- ions showed no potential overshoot followed by a rapid potential decay, the potential transients in the presence of HSO4- ions showed an appreciable potential overshoot followed by a slow potential decay. This means that pit and etch tunnel growth is accelerated by the addition of SO42- and S2O32- ions, but it is retarded by the addition of HSO4- ions. Based upon experimental results, two types of mechanisms for increased surface area in the presence of SO42-, S2O32- and HSO4- ions are proposed: increase in surface area by enhancing growth rate of etch tunnels in the pre-existing pits in the presence of SO42-, S2O32- ions; increase in surface area by increasing both the pit number density and the pit area density in the presence of HSO4- ions. Keywords: aluminium, sulphate, thiosulphate, hydrogen sulphate, capacitor Introduction Aluminium (Al) electrolytic capacitors are widely used in all types of electronic equipment because they have wide working potential range with favourable economics. Since the capacitance of Al foil used in electrolytic capacitor is determined by its surface area, electrochemical etching process has been adopted to increase surface area. For high voltage application, DC etching which forms long etch tunnels is demanded rather than surface etching [1, 2]. Over the past few decades, a considerable number of studies have been made on the metal dissolution kinetics [3], the passivation of the oxide film in Al etch tunnels during the electrochemical etching [4] and the morphological study of Al etch tunnels by using scanning electron microscopy (SEM) [5, 6]. There are many factors which influence tunnel etching. Among them, the well discussed factors are the properties of Al foil such as impurities, grain size, cubicity and the properties of etching solution such as composition and temperature of etching solution and finally, etching time. In general, etching process is done in a hot chloride solution at temperatures above 70°C. In the initial attack, crystallographic cubic etch pits form. Since the pit walls grow in five directions simultaneously, the depth of etch pits is half the width at the surface [7]. When the pit width increases to about 1 µm, there is a change in growth morphology. The formation of etch tunnels from the existing etch pits and subsequent their growth along [100] direction occur [1]. In contrast, below 60 °C, etch pits coalesce into large pits without any change in morphology. Since the shape of etch tunnels is influenced by the additives in the solution, various additives for increased surface area have been employed. Among them, sulphate (SO42-) is the most common. In previous work [8, 9], the effect of sulphate ion additives on pitting corrosion of pure Al was investigated at room temperature 2 by observing how pit morphology depends on SO42- ion concentration. It was revealed that the addition of SO42- ions retards pit initiation and at the same time accelerates Al dissolution in the pits. In addition, the beneficial effect of thiosulphate (S2O32-) and hydrogen sulphate (HSO4) ion additive was also reported [10]. In the present work, effects of SO42-, S2O32- and HSO4- ion additives on electrochemical etching of pure Al foil were examined in 4 M sodium chloride (NaCl) solution as a function of anion concentration using potentiodynamic polarisation experiment, galvanostatic potential transient technique, electrochemical impedance spectroscopy and scanning electron microscopy (SEM). The experimental results are discussed in terms of the changes in etch tunnel morphology and surface area in the presence of anion additives. Experimental The test specimen used in this work was high purity (99.99%), 120 µm thick aluminium (Al) foil. The chemical composition of the foil used in this study was determined by ICP-AES (Inductively Coupled Plasma Atomic Emission Spectrometry) and is shown in Table 1. Table 1 Impurity concentration in Al foil (in wt ppm). Fe Si Cu Mg Zn Mn Cr Ni Ti Pb In 9.28 8.63 48.2 1.31 7.45 <1.0 <1.0 <2.0 <2.0 <5.0 <20 The Al foil was pretreated before etching by immersion in 1 M NaOH solution at room temperature for 10 min to enhance uniformity of the distribution of tunnel lengths and widths [11]. In all electrochemical experiments, a platinum gauze and a saturated calomel electrode (SCE) were used as the counter and reference electrodes, respectively. Pitting potential, Epit, of Al foil in the absence of SO42-, S2O32- and HSO4- ions was compared with that of Al foil in the presence of these ions by potentiodynamic polarisation experiments. Measurements were made at a scan rate of 0.5 mVs-1 in the applied potential range from open-circuit potential to –0.4 VSCE by using an EG&G model 263A galvanostat/potentiostat. 3 Etching was carried out in 4 M NaCl solution containing various SO42-, S2O32- and HSO4- ion concentrations at 80°C at a constant current density of 100 mAcm-2. To investigate the effect of SO42-, S2O32- and HSO4- ion addition on initiation and growth of pits and etch tunnels, the potential was recorded galvanostatically with time. Fig. 1 demonstrates schematic diagram of applied wave form for double current step experiment. In stage I, pits and etch tunnels were first formed by applying a constant anodic current density of 100 mAcm-2. After that(stage II), pre-existing pits and etch tunnels were passivated during current interruption. In stage III, galvanostatic potential transients resulting just after current interruption were analysed to investigate the effect of anion addition on growth of pits Applied Current Density / mAcm -2 and etch tunnels. 100 I II III 0 Interruption time, tin 5s Time / s Fig. 1. Schematic diagram of applied current wave form for double current step experiment. The oxide film formed on the etched Al foil by anodising in 0.5 M H3BO3 + 0.05 M Na2B4O7 solution to determine the oxide film capacitance from electrochemical impedance spectra and, at the same time, to examine pits and etch tunnels by SEM. The current density of 0.5 mAcm-2 was applied until 30V was reached, and then the foil was held at 30V for a further 30 min. 4 Electrochemical impedance measurements were conducted on the anodized Al foil in 0.5 M H3BO3 + 0.05 M Na2B4O7 solution by using an Electrochemical Measurement Unit (Zahner IM6e impedance analyser) to determine the oxide film capacitance of Al foil. Ac signal of 5 mV amplitude was superimposed on open-circuit potential at room temperature over the frequency range of 10-1 Hz to 105 Hz. The measured impedance spectra were analysed using the complex nonlinear squares (CNLS) fitting method based upon the simple Randles circuit [12, 13]. The morphology of pits and etch tunnels was observed using the oxide replication technique [14]. Al was dissolved from the anodised foil by immersion in bromine-methanol solution. After that, the remained oxide replica was observed by using SEM. Results and Discussion Fig. 2 presents the XRD pattern of Al foil obtained by theta-two theta scanning method for examining preferred orientation. In this figure, it was shown that the diffraction peak from (200) plane was the most dominant. Therefore, it is evident that the surface of Al foil mainly consists of (100) plans. Fig. 3 shows the typical SEM micrograph of the oxide replica of the Al foil etched in 4 M NaCl solution at 80°C at an anodic current density of 100 mAcm-2 for 40 s. It was observed that most of etch tunnels grew in the direction perpendicular to the surface of Al foil. Considering that etch tunnels grow preferentially along [100] direction in a hot chloride solution as mentioned in introduction, This is another indication that Al foil used in this work has (100) preferred orientation. Fig. 4 depicts anodic polarisation curves of Al foil with a scan rate of 0.5 mVs-1 in 4 M NaCl solution containing various anion concentrations at 80 °C. Figs. 4(a) and 4(b) showed that pitting potential, Epit shifted to more positive values as SO42- and S2O32- ion concentrations increased. This implies that pit initiation is suppressed by the addition of SO42- and S2O32- ions. In contrast, Fig. 4(c) showed the decrease in Epit with the addition of HSO4- ions. It indicates that pit initiation is accelerated by the addition of HSO4- ions. 5 1200 (200) 800 600 400 (111) 200 0 20 (311) (220) 40 60 Fig. 3. Typical SEM micrograph of the oxide 80 replica of the Al foil etched in 4 M NaCl at Scanning Angle 2θ / degree 80°C at an anodic current density of 100 mAcm-2 for 40 s. Fig. 2. XRD pattern of Al foil used in this work. -0.2 4M NaCl 4M NaCl + 0.01M Na2SO4 4M NaCl + 0.1M Na2SO4 4M NaCl + 0.3M Na2SO4 -0.4 -0.6 4M NaCl 4M NaCl + 0.01M Na2S2O3 4M NaCl + 0.1M Na2S2O3 4M NaCl + 0.3M Na2S2O3 -0.4 Applied Potential / VSCE Applied Potential / VSCE -0.2 -0.8 -1.0 -0.6 -0.8 -1.0 -1.2 -1.2 -1.4 -10 10 -1.4 -9 10 -8 -7 10 10 -6 10 -5 10 -4 10 -3 -2 10 10 1 -1 10 -7 10 -6 10 -5 10 -4 10 -3 -2 10 10 (a) (b) pure Al foil with a scan rate of 0.5 mVs-1 in 4 M NaCl solution containing various anion concentrations at 80 °C: (a) SO42-, (b) S2O32- and (c) HSO4-. -1.0 -1.2 -9 10 -8 10 -7 10 -6 10 -5 10 -4 10 -3 -2 10 10 1 -1 10 -2 Current Density / Acm (c) -1 10 Fig. 4. Anodic polarisation curves of -0.8 -1.4 -10 10 -8 10 Current Density / Acm 4M NaCl 4M NaCl + 0.01M NaHSO4 4M NaCl + 0.1M NaHSO4 4M NaCl + 0.3M NaHSO4 -0.6 -9 10 Current Density / Acm -0.2 -0.4 -1.6 -10 10 -2 -2 Applied Potential / VSCE Intensity / arbitrary unit 1000 6 1 Fig. 5 demonstrates galvanostatic potential transients of Al foil subjected to a constant anodic current density of 100 mAcm-2 in 4 M NaCl solution containing various anion concentrations at 80 °C. In this figure, the potential transients were divided into three stages: the initial increase in potential up to the maximum value in the first stage, the decrease in potential after the maximum in the second stage and the stabilisation of potential to a constant value in the final stage. The increase in potential in the first stage is associated with double layer charging and oxide growth, while the decrease in potential in the second stage is ascribed to the breakdown of oxide film and to subsequent pit and etch tunnel initiation. A constant value in potential in the final stage indicates the steady growth of pits and etch tunnels [15, 16]. Potential and time at the maximum are denoted as the maximum potential, Emax, and the induction time, ti, respectively. Since the breakdown of oxide film and subsequent initiation of pits 2.0 1.8 1.6 ti 1.4 4M NaCl 4M NaCl + 0.01M Na2S2O3 4M NaCl + 0.1M Na2S2O3 4M NaCl + 0.3M Na2S2O3 1.0 0.8 Potential / VSCE 1.2 Potential / VSCE 1.2 4M NaCl 4M NaCl + 0.01M Na2SO4 4M NaCl + 0.1M Na2SO4 4M NaCl + 0.3M Na2SO4 Emax 1.0 0.8 0.6 0.4 0.2 0.0 0.6 0.4 0.2 0.0 -0.2 -0.2 -0.4 -0.4 -0.6 -0.6 -0.8 -0.8 0 0.02 0.04 0.06 0.08 0.10 0.12 0.14 0.16 0.18 0.20 0 Etching Time / s Potential / VSCE 0.6 0.08 0.10 Fig. 5. Galvanostatic potential transients of pure Al foil subjected to a constant anodic current density of 100 mAcm-2 in 0.4 4 M NaCl solution containing various 0.2 anion concentrations at 80 °C: (a) SO42-, (b) S2O32- and (c) HSO4-. 0.0 -0.2 -0.4 -0.6 -0.8 0.06 (b) 4M NaCl 4M NaCl + 0.01M NaHSO4 4M NaCl + 0.1M NaHSO4 4M NaCl + 0.3M NaHSO4 0.8 0.04 Etching Time / s (a) 1.0 0.02 0 0.02 0.04 0.06 0.08 0.10 Etching Time / s (c) 7 and etch tunnels occur at Emax and ti, higher value in Emax and ti indicates higher resistance to pit and etch tunnel initiation. In the case of SO42- and S2O32- ion addition, it was found that both the Emax and ti increased with increasing SO42- and S2O32- ion concentration as shown in Figs. 5(a) and (b). This implies that the initiation of pits and etch tunnels is more retarded in SO42-- and S2O32--containing NaCl solution than in SO42-- and S2O32--free NaCl solution. In contrast, it was observed that both the Emax and ti decreased with increasing HSO4- ion concentration as shown in Fig. 5(c). Therefore, it can be said that pits and etch tunnels are more easily initiated in HSO4--containing NaCl solution than in HSO4--free NaCl solution. Fig. 6 shows galvanostatic potential transients resulting just after current interruption in the double current step experiment in anionfree and anion containing 4 M NaCl solutions. In the case of anion-free 4 M NaCl solution, a significant potential overshoot was observed at the current interruption time of 0.04 s as shown in Fig. 6(a). This means that the time required for the passivation of pits and etch tunnels is at least longer than 0.04 s in the absence of anions. In the presence of SO42- and S2O32- ions (Figs. 6(b) and 6(c)), the potential overshoot at the current interruption time of 0.08 s was higher than that in the absence. This is another indication that pit and etch tunnel initiation is suppressed in the presence of SO42- and S2O32- ions. However, at relatively short current interruption times, more remarkably reduced potential overshoot appeared, followed by a more rapid potential decay compared with that in the absence. Considering that pits and etch tunnels become still active as the current interruption time decreases, it indicates that the addition of SO42- and S2O32- ions accelerates pit and etch tunnel growth. In contrast, the potential overshoot at relatively short current interruption times in the presence of HSO4- ions (Figs. 6(d)) is higher than that in the absence, implying that the addition of HSO4- ions retards pit and etch tunnel growth. Summarising the results of Fig. 6, we can depict a schematic diagram of potential transients resulting just after current interruption as given in Fig. 7. The potential transients resulting just after current 8 interruption appear in the following two forms: one is an appreciable potential overshoot followed by slow potential decay (type A) and the other is no potential overshoot followed by rapid potential decay (type B). When pits and etch tunnels are entirely passivated during the current interruption, it is expected that the potential transient of type A appears. However, the potential transient of type B occurs when pits and etch tunnels are partly passivated and still active during the current interruption. 0.6 0.2 0.08 s -0.2 0.2 Potential / VSCE 0.04 s 0.0 Potential / VSCE 0.08 s 0.4 0.02 s -0.4 0.01 s -0.6 0.005 s 0.0 -0.2 0.04 s -0.4 0.02 s -0.6 -0.8 0.01 s -0.8 0.005 s -1.0 -1.0 -1.2 -1.2 0 0.005 0.010 0.015 0.020 0.025 0.030 0.035 0.040 0 0.005 0.010 0.015 Time / s 0.020 0.025 0.030 0.035 0.040 0.07 0.08 Time / s (a) (b) 0.6 0.6 0.08 s 0.4 0.08 s 0.4 0.2 Potential / VSCE Potential / VSCE 0.2 0.0 0.04 s -0.2 -0.4 -0.6 0.01 s 0.02 s 0.005 s -0.8 -0.4 0.02 s 0.01 s 0.005 s -0.8 -1.2 -1.4 -0.2 -0.6 -1.0 0.04 s 0.0 -1.0 0 0.005 0.010 0.015 0.020 0.025 0.030 0.035 0.040 Time / s 0 0.01 0.02 0.03 0.04 0.05 0.06 Time / s (c) (d) Fig. 6. Galvanostatic potential transients resulting just after current interruption in (a) 4 M NaCl, (b) 4 M NaCl + 0.3 M Na2SO4, (c) 4 M NaCl + 0.3 M NaS2O3 and (d) 4 M NaCl + 0.3 M NaHSO4 at 80 °C. 9 A Potential Potential overshoot B Time Fig. 7. Schematic diagram of potential transients resulting just after current interruption. Figs. 8 through 10 depict SEM micrographs of pit morphology on the surface of Al foil subjected to a constant anodic current density of 100 mAcm-2 for 3 s in 4 M NaCl solution containing various SO42-, S2O32and HSO4- ion concentrations, respectively. In Fig. 8 and 9, it was apparent that both the pit number density and the pit area density decreased as SO42- and S2O32- ion concentrations increased. On the contrary, there was an increase in the pit number density and the pit area density with increasing HSO4- ion concentration as shown in Fig. 10. In addition, it was worthwhile to note that etch pits up to a few µm in size were mainly observed in 4 M NaCl solution at higher magnification. Figs. 11 (a) through (d) demonstrate SEM micrographs of the oxide replica of pure Al foil subjected to a constant anodic current density of 100 mAcm-2 for 40 s in 4 M NaCl, 4 M NaCl + 0.3 M Na2SO4, 4 M NaCl + 0.3 M Na2S2O3 and 4 M NaCl + 0.3 M NaHSO4 solutions, respectively. While etch tunnels were uniformly distributed in the absence of SO42-, S2O32- and HSO4- ions as shown in Fig. 11(a), etch tunnels were only formed in the pre-existing pits in the presence of SO42- and S2O32- ions as shown in Fig. 11(b) and (c). But the average etch tunnel length 10 (a) (b) (c) (d) Fig. 8. SEM micrographs of pit morphology on the surface of Al foil subjected to a constant anodic current density of 100 mAcm-2 for 3 s in 4 M NaCl solution containing various SO42- ion concentrations at 80 °C: (a) 0 M, (b) 0.01 M, (c) 0.1 M and (d) 0.3 M. in the presence of SO42- and S2O32- ions was longer than that in the absence, resulting in larger surface area. In the case of HSO4- (Fig. 11(d)), the average etch tunnel length is shorter that that in the absence. But both the pit number density and the pit area density are higher in the presence than those in the absence. This also leads to larger surface area. 11 (a) (b) (c) (d) Fig. 9. SEM micrographs of pit morphology on the surface of Al foil subjected to a constant anodic current density of 100 mAcm-2 for 3 s in 4 M NaCl solution containing various S2O32- ion concentrations at 80 °C: (a) 0 M, (b) 0.01 M, (c) 0.1 M and (d) 0.3 M. Fig. 12 illustrates changes in the value of the measured oxide film capacitance for the anodised Al foil in 0.5 M H3BO3 + 0.05 M Na2B4O7 solution with SO42-, S2O32- and HSO4- ion concentrations during etching. To determine the oxide film capacitance of the anodised Al foil, the measured impedance spectra were analysed using the CNLS fitting method based upon the simple Randles circuit. In this figure, it appeared that the oxide film capacitance increased with increasing SO42-, S2O32- and HSO4- ion concentrations. The oxide film capacitance A Cox is proportional to the area A as C ox = ε 0 ε r . Here A and d are the d 12 (a) (b) (c) (d) Fig. 10. SEM micrographs of pit morphology on the surface of Al foil subjected to a constant anodic current density of 100 mAcm-2 for 3 s in 4 M NaCl solution containing various HSO4- ion concentrations at 80 °C: (a) 0 M, (b) 0.01 M, (c) 0.1 M and (d) 0.3 M. area and the oxide film thickness, respectively and ε 0 and ε r represent the absolute ( ε 0 =8.85×10-12 Fm-1) and the relative permittivity constants, respectively. Accordingly, it can be inferred that the increase in the value of Cox by the addition of SO42-, S2O32- and HSO4ions to a chloride solution is caused by the increase in surface area. 13 (a) (b) (c) (d) Fig. 11. SEM micrographs of the oxide replica of pure Al foil subjected to a constant anodic current density of 100 mAcm-2 for 40 s in (a) 4 M NaCl, (b) 4 M NaCl + 0.3 M Na2SO4, (c) 4 M NaCl + 0.3 M NaS2O3 and (d) 4 M NaCl + 0.3 M NaHSO4 at 80 °C. Hence, from the experimental findings, two types of mechanisms for increased surface area in the presence of SO42-, S2O32- and HSO4- ions are proposed: - The addition of SO42-and S2O32- ions retards pit and etch tunnel initiation but it enhances growth of etch tunnels in the pre-existing pits. The increased surface area is due mainly to the fact that the retarding contribution to pit and etch tunnel initiation is overwhelmed by the enhancing contribution to etch tunnel growth. 14 1500 1500 1000 500 0 5 10 15 20 25 30 35 40 45 Etching Time / s (a) 500 0 5 10 15 20 25 30 35 40 45 (b) 4M NaCl 4M NaCl + 0.01M NaHSO4 4M NaCl + 0.1M NaHSO4 4M NaCl + 0.3M NaHSO4 -2 1000 Etching Time / s 1500 Measured Oxide Film Capacitance / µFcm 4M NaCl 4M NaCl + 0.01M Na2S2O3 4M NaCl + 0.1M Na2S2O3 4M NaCl + 0.3M Na2S2O3 -2 Measured Oxide Film Capacitance / µFcm Measured Oxide Film Capacitance / µFcm -2 4M NaCl 4M NaCl + 0.01M Na2SO4 4M NaCl + 0.1M Na2SO4 4M NaCl + 0.3M Na2SO4 Fig. 12. Changes in the values of the measured oxide film capacitance for 1000 the anodized Al foil in 0.5 M H3BO3 + 0.05 M Na2B4O7 solution at 25° C. The specimens were previously etched in 4 500 M NaCl solution containing various anion concentrations at 80 °C: (a) SO42-, (b) S2O32- and (c) HSO4-. 0 5 10 15 20 25 30 35 40 45 Etching Time / s (c) - The addition of HSO4- ions enhances pit and etch tunnel initiations but it retards growth of etch tunnels in the pre-existing pits. The increased surface area results from the increase in the pit number density and pit area density. Conclusions 1. Pitting potential, Epit, in the potentiodynamic polarisation curves and the maximum potential, Emax, and induction time, ti, in the galvanostatic potential transients increased with increasing SO42- and S2O32- ion concentrations in the NaCl solution, implying the inhibition 15 of pit and etch tunnel initiation. In contrast, as HSO42- ion concentration increased, Epit, Emax and ti decreased as well. This suggests that the addition of HSO42- ions to NaCl solution enhances pit and etch tunnel initiation. 2. Galvanostatic potential transients resulting just after short current interruption in the presence of SO42- and S2O32- ions showed no potential overshoot followed by a rapid potential decay. In contrast, the potential transients in the presence of HSO4- ions showed an appreciable potential overshoot followed by a slow potential decay. This indicates the acceleration of pit and etch tunnel growth by the addition of SO42- and S2O32- ions and the retardation of pit and etch tunnel growth by the addition of HSO4- ions. 3. From the measured oxide film capacitance Cox obtained from the impedance spectra of the anodised Al foil specimens, it was obviously shown that the addition of SO42-, S2O32- and HSO4- ions to a chloride solution increased the value of Cox. 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