Typically, the work-piece is immersed in a temperature-controlled bath of electrolyte and serves as the anode; it is connected to the positive terminal of a DC power supply, the negative terminal being attached to the cathode. A current passes from the anode, where metal on the surface is oxidised and dissolved in the electrolyte, to the cathode. At the cathode, a reduction reaction occurs, which normally produces hydrogen. Electrolytes used for electropolishing are most often concentrated acid solutions such as mixtures of sulfuric acid and phosphoric acid. Other electropolishing electrolytes reported in the literature include mixtures of perchloric acid with acetic anhydride (which has caused fatal explosions), and methanolic solutions of sulfuric acid.
To electropolish a rough surface, the protruding parts of a surface profile must dissolve faster than the recesses. This process, referred to as anodic leveling, can be subject to incorrect analysis when measuring the surface topography. Anodic dissolution under electropolishing conditions deburrs metal objects due to increased current density on corners and burrs.
Most importantly, successful electropolishing should operate under diffusion limited constant current plateau, achieved by following current dependence on voltage (polarisation curve), under constant temperature and stirring conditions.