Discover our complete solutions portfolio covering Cathodic Protection and Corrosion management - PCB design and plating - Functional and decorative plating - Electrocoating - Acoustics
Elsyca V-PIMS
A revolution in digital PIMS combining Pipeline Corrosion Integrity Management System (PIMS) and computational modeling capabilities
Elsyca IRIS
Deep analysis of AC threats supporting efficient mitigation systems computer-aided design
Elsyca CatPro
Graphical simulation platform for cathodic protection and DC stray current analysis of pipeline networks
Elsyca CPManager
3D CAD-based software simulation platform for the computer-aided design and analysis of cathodic protection installations
Elsyca ACTA
Unique solution offering accurate, disambiguated, and tailored risk ranking report of pipeline networks
Elsyca PlatingManager
Leverage a digital twin of your plating line to predict plating performance and increase manufacturing capacity
Elsyca PCBBalance
The world’s only PCB DFM software that applies automated and optimized copper balancing to your PCB design and panel layout.
Elsyca PCBPlate
State-of-the-art graphical simulation platform for enhancing the plating performance of your PCB panel and pattern plating processes.
Elsyca ECoatMaster
CAD independent software platform for the simulation of the automotive electrocoating process of a body-in-white (BIW).
Elsyca EPOS
Simulate the performances of electropolishing processes based on a virtual mock-up of the electropolishing cell.
Elsyca AnodizingManager
State-of-the-art graphical simulation platform for analyzing the production performance and quality of anodizing processes.
Elsyca CorrosionMaster
CorrosionMaster identifies corrosion hot spots and predicts corrosion rates, enabling engineers to look at alternative material combinations and/or coating systems, or investigate corrosion-mitigating measures.
Elsyca LeakageMaster
Improve vehicles interior acoustic comfort by performing upfront virtual smoke tests.
Elsyca MeshingMaster
Automatically creates meshes for a variety of applications such as acoustics, CFD, thermal analysis, etc
Elsyca XPlorer
Interactive simulation results viewer for Finite Elements results
Elsyca XPlorer3D
Analyze, Understand and Get Immersed in your results

Continuous anodizing of aluminum foil

Assessing the capabilities of process simulation software to predict the standard working conditions of the different anodizing configurations

Continuous anodizing of aluminum foil


The first step of the project is to assess the capabilities of process simulation software to predict the standard working conditions of the different anodizing configurations (both horizontal and vertical) by comparing the calculated results with measurements and macroscopic process conditions. 

Also, a sensitivity analysis is performed to quantify the interactions between the electrolyte flow, the electrical potential, the current density, the web thickness, the web speed, and the temperature distributions in the reactor. This includes a parameter study to investigate the influence of the different process parameters (flow rate, web velocity, web thickness, total current,…) on the local conditions (current density, temperature, and overpotential) of the anodizing process. 


The project clearly demonstrates the possibilities of the present state-of-the-art modeling on industry-scale anodizing reactors. In the second step, the optimization with respect to quality control and a higher web speed for the different production lines is investigated and implemented successfully at the different production sites.


Based on an extensive validation study, a very good quantitative agreement between all macroscopic parameters like the potential of the rectifier and temperature increase in the electrolyte has been established. The simulations increase significantly the insight in the behaviour and the most critical parameters of the process and open the way to better process control and faster throughput.