How should a localized detachment of the electrode coating be handled? Essential Maintenance and Assessment Guide

Immediate system shutdown is mandatory upon detecting any localized detachment of the electrode coating. You must pause operations to perform a thorough visual inspection of the damage; if the detached area covers less than 5% of the total surface, you may continue operation at a reduced current, but extensive damage requires the complete replacement of the electrode.

Core Takeaway Coating detachment is a sign of critical stress, typically caused by physical impact or electrical overload. While minor damage allows for temporary, low-output operation, the electrode’s protective barrier is compromised, making replacement the only permanent solution for extensive failure.

Immediate Response and Diagnosis

Initiating a Safety Shutdown

The moment coating detachment is identified, you must shut down the system. Continued operation without assessment can lead to rapid failure of the substrate or contamination of the electrolytic environment.

Identifying the Root Cause

During inspection, you must determine what triggered the failure to prevent recurrence. The two primary drivers are usually collision during installation, resulting in mechanical impact, or excessive current density, which thermally or chemically stresses the coating bond.

Assessing Damage Severity

The 5% Threshold

The viability of the electrode depends strictly on the surface area of the loss. If the total detached area is less than 5% of the electrode's total surface, the component is not yet a total loss.

Criteria for Replacement

If the inspection reveals that the detached area is extensive (exceeding 5%), the electrode cannot be salvaged. It must be replaced immediately to ensure process stability and safety.

Understanding the Trade-offs

Reduced Output vs. Continuity

If you choose to keep an electrode with minor damage (<5%) in service, you must operate at a reduced current. This allows you to maintain uptime, but it inevitably creates a bottleneck in production capacity or efficiency.

Risks of Extended Operation

Operating a damaged electrode is a stop-gap measure, not a permanent fix. The exposed area creates a vulnerability where the substrate may degrade faster, potentially leading to sudden failure even at reduced loads.

Making the Right Operational Decision

Deciding between repair, reuse, or replacement depends on your immediate production constraints and risk tolerance.

• If your primary focus is Production Continuity: Restart the system with the damaged electrode only if the loss is less than 5%, and strictly limit the current to prevent further peeling.
• If your primary focus is System Integrity: Replace the electrode immediately if the damage is extensive, as the risk of substrate corrosion and process instability outweighs the cost of a new component.

Adhere strictly to the 5% damage limit to balance operational needs with equipment safety.

Summary Table:

Assessment Factor	Detail	Recommended Action
Damage Threshold	< 5% of total surface area	Operate at reduced current output
Damage Threshold	> 5% of total surface area	Immediate replacement required
Primary Causes	Physical impact or current overload	Inspect installation and density settings
System Status	Detection of detachment	Immediate mandatory system shutdown
Risk Level	High (Exposed substrate)	Monitor for corrosion or process instability

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