Simulation of aluminium electrodeposition on complex geometry: Influence of input parameters and electrodeposition conditions

•The redox process of Al2Cl7−/AlCl4− was a quasi-reversible process. At 318.15 K, the cathodic and anodic transfer coefficients were calculated to be 0.136 and 0.864, and the exchange current density for Al2Cl7−/AlCl4− redox process was calculated as 4.6A/m2.•An electrodeposition model combined secondary current distribution, laminar flow, and transport of diluted species was constructed.•The main process parameters (distance between anode and cathode, applied voltage, and deposition temperature) play significant roles in the acceleration of the electrodeposition rate and improvement of the current efficiency of electrodeposited Al.•The results of the Al coating thicknesses from finite element simulation agree well with the experiment method.