Sacrificial anodes are an essential component of marine corrosion protection. However, their performance depends on the simultaneous optimization of competing properties, including efficiency, current density, and current output. This study applies response surface methodology (RSM) with a desirability function approach (DFA) to optimize the performance of Al–Zn–Mg–Sn sacrificial anodes. Sn content, ageing temperature, and time were varied to evaluate their influence on current, current density, and anode efficiency in synthetic seawater using gravimetric tests based on ASTM G1-03. Quadratic regression models were developed and assessed using ANOVA, R², RMSE, and MAE. Results indicate that Sn content and ageing temperature significantly affect performance, with optimum conditions of 0.045% Sn, 175 °C, and 8 h yielding near-98% efficiency alongside improved current density and output. Model reliability was confirmed through cross-validation, with errors below 5%. The results suggest that DFA-based multi-response optimization offers a practical and transferable framework for concurrently balancing competing electrochemical properties in marine sacrificial anode design.

Keywords

Sacrificial anodes, Al–Zn–Mg–Sn alloys, Gravimetric testing, Response surface methodology (RSM), Desirability function approach (DFA).