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You do need to keep a certain current... the larger the surface, the more current you need to push. You are litterally shooting electrons from one part to another... a big flat part needs LOTS of current and can quickly overload a power supply (water is essentially a dead short).

Not really a new process. I've used it for over 4 years. Lye works the best... but washing soda is a good substitute. Its not really for large parts as the removal is line of sight... so using a slight acid (vinegar, molasses etc) works much better for nooks and crannies. Plus you must be...