[rclint]

So if you have a sqaure piece of sheet aluminum (we wil not count sides because it's so thin) 4" tall by 5" wide

With the 3 amp power supply your talking about here is what it could come out as

4"x5"=20" you have two sides, so 20" x 2 = 40" total

You would run in CC mode, set the amps to 1.67 for a 6 amp current density run 84 minutes for a .7 mil coating

Hope this helps you figure out how to calculate the surface area compared to current density and what size power supply you need. On a normal part you measure out everything as close as you can for the square inches, then add them all up.

Clint