Arc Plasma Research Articles

Effect of ZrC particle on microstructure and corrosion behavior of CoCrNi medium-entropy alloy fabricated by powder plasma arc cladding

Medium-entropy alloys (MEAs) show significant potential as corrosion-resistant coatings. However, their industrial applications are limited by fabrication challenges and low efficiency. This study synthesized CoCrNi(ZrC)x MEA coatings using powder plasma arc cladding (PPAC) technology. The CoCrNi(ZrC)x MEAs consist of columnar and equiaxed grains. Incorporating ZrC refines the grain structure, achieving maximum refinement at x = 3. This refinement enhances the coating hardness by approximately 40 % (from 165 ± 3.36 to 229 ± 4.83 HV0.1), mainly due to Hall-Petch strengthening, solid solution effects, and grain boundary and dispersion strengthening. In 3.5 wt% NaCl solution, corrosion resistance was notably improved, as evidenced by a substantial decline in corrosion pits and an 81 % (from 4.52 to 0.86 μA/cm²) reduction in icorr. This enhancement is primarily due to ZrC reducing the exposed surface area of the coating and providing protection through localized Cr segregation at anodic sites. This study is the first to introduce ZrC ceramic particles into CoCrNi MEAs, advancing the development of corrosion-resistant coatings.

Effects of anode evaporation process on the anode sheath characteristics in vacuum arc plasma

Abstract The anode sheath of vacuum arc plasma plays a key role in the generation of anode plasma, but the effects of anode evaporation on the anode sheath remains unclear. In this paper, a theoretical model of a collisional sheath for multi-component plasma coupled with anode evaporation is developed, and the spatial evolution of the anode sheath at different anode surface temperatures is investigated. The results indicate that the distribution of charged particles density and potential in the anode sheath monotonically decreases in the absence or reduction of anode evaporation. When the anode surface temperature exceeds 1900K, a potential hump appears within the sheath. This is due to enhanced anode evaporation increasing the metal vapor density, which intensifies electron impact ionization and charge exchange collisions, resulting in a higher net space charge density. Finally, the effects of various collision reactions and electron temperatures on the potential hump are analyzed. These findings are meaningful for understanding the anode plasma generation mechanism and regulating the anode plasma parameters.

Comparative investigation on the microstructure and corrosion properties of surfacing cobalt alloys by various methods

This study applies three different welding methods, namely tungsten inert gas (TIG) welding, laser welding, and plasma arc welding, to perform cobalt alloy surfacing on austenitic stainless steel substrates, and compares their microstructure and corrosion properties. The results reveal that samples obtained through all three methods exhibit excellent metallurgical bonding between the austenitic stainless steel substrate and the cobalt alloy surfacing layer, with no observed defects such as cracks, pores, or inclusions. Among them, the cobalt alloy surfacing layer produced by laser welding shows a finer and more uniform microstructure, displaying a distinct growth direction along the surfacing direction away from the interface. Additionally, electrochemical polarization curve testing demonstrates that the corrosion resistance of the laser-welded surfacing layer surpasses that of TIG welding and plasma arc welding, exhibiting a lower corrosion rate. This study offers valuable insights into the selection of cobalt alloy surfacing welding methods on austenitic stainless steel substrates and the evaluation of the corrosion properties for the cobalt alloy surfacing layer, providing essential guidance for engineering practices in the power plant valves.

Construction of high-efficiency Fe-MnO@Fe electrocatalyst for methanol and ethanol oxidation in alkaline medium

Abstract Acquiring effective, durable and economical non-precious metal electrocatalysts is crucial for the widespread utilization of fuel cells. In this work, an iron/manganese oxide nanocomposite (Fe-MnO@Fe) is synthesized as a novel electrocatalyst by direct-current (DC) arc plasma technology integrating transition metal and transition metal oxide. The Fe-MnO@Fe catalyst demonstrates excellent catalytic performance. By modulating the percentage of transition metal and transition metal oxide in the composite, the largest current density values of methanol and ethanol oxidation of the composite reach 20.18 and 7.83 mA/cm2, respectively. In addition, the composite catalyst exhibits excellent stability and conductivity, and the catalyst greatly reduces the experimental cost relative to the noble metal catalysts, indicating that the composite is a potential fuel cell catalyst candidate and provides an innovative concept for creation non-precious metal catalysts.

Effect of Feedstock Blends and Equivalence Ratio on the Thermal Arc Plasma Assisted Co-Gasification of Biomass and Plastic using Air-Blown Downdraft Reactor

Plastic waste is known to cause an emerging environmental pollution, posing risks to both terrestrial and aquatic ecosystems. Co-gasification method is an alternative way to reduce municipal solid waste and plastic waste by converting it into useful gas fuel energy. The present study used empty fruit bunch biomass (EFB), plastic waste of low-density polyethylene (LDPE) and Polyethylene terephthalate (PET) as a feedstock for thermochemical conversion process into syngas fuel energy via plasma co-gasification method. The effect of multiple feedstocks mixture between biomass and plastic and equivalence ratio on the compositions of produced syngas, high heating value (HHV), lower heating value (LHV), cold gas efficiency (CGE) and carbon conversion efficiency (CCE) were critically investigated. A reactor of air-blown downdraft arrangement was used in these experiments. The gasifying agent flow rate of air was set at the frequency range of 10 to 22Hz to achieve equivalence ratio between 0.15 to 0.30. The blending ratio (BR) between biomass and plastic (EFB:Plastic) were set as E90:P10, E80:P20 and E70:P30. The results indicate that H2 and CO composition is typically decrease as ER increase for the mixture of EFB and LDPE. In contrast, the composition of H2 and CO is generally increase as ER increases. However, the maximum value of H2 and CO is dominated by the mixture of EFB and LDPE at any blending ratio and lower ER condition. This is due to the higher element of H, C and O in the raw material of EFB and LDPE compared to PET. This study is crucial in understanding the synergistic effect of co-gasification assisted with plasma reaction between biomass and plastic waste.

Diagnostic study on laser-produced metal hydride plasmas

The characteristics of laser-produced metal hydride plasmas have been investigated in this work. The charge state and velocity of ions were determined by employing a time-of-flight technique in conjunction with an electrostatic deflection method. The ion velocities were found to be supersonic with values in the range of 104 to 105 m/s. The proportion of hydrogen ions was found to be lower than that of titanium ions. The ion emission behavior was studied by using a Faraday cup. When the total integrated space was taken into account, the ns pulsed laser was capable of producing hydrogen ion currents greater than one hundred mA. In order to understand the plasma generation process, we performed a comparative analysis between laser-generated plasma and arc plasma, and also investigated the effect of laser power density on the composition and velocity of the ions, the ablation properties of metal hydrides, and the maintainability of hydrogen ion emission.

Numerical analysis and Schlieren visualization of gas flow dynamics inside the plasma arc cut kerf with curved cutting fronts

In plasma arc cutting (PAC), the characteristics of the gas flow exiting the nozzle significantly influence the cut quality. The high-pressure jet in PAC forms complex shockwave structures when it is incident on the metal to be cut. In this study, the flow behavior inside the kerfs of various geometries derived from an actual PAC workpiece is assessed. The shape of the cutting front in the kerf varies with the changing cutting speed. A high cutting speed yields a curved cutting front, resulting in unwanted gas flow behavior and adversely influencing the cutting performance. In this study, a computational fluid dynamics simulation model was used to analyze the effects of a curved cutting front on the gas flow behavior during the PAC process. The gas flow patterns obtained from the numerical simulations were qualitatively compared with the Schlieren experiment results. The analysis results indicated that the curvature of the cutting fronts generated oblique shockwave structures that significantly reduced the flow velocity. In particular, the weak shock structures throughout the curved cutting front gradually decreased the flow velocity. The critical flow velocity was realized in the kerf with a highly curved cutting front, beyond which the vertical penetration of the material was not possible. The shear stress lines concurred with the striation patterns on the kerf walls, thereby validating the numerical analysis results.

Закономерности износа плазмотронов при плазменной резке толстолистового проката на токе обратной полярности

The introduction describes the features of the process of plasma cutting of various metals and alloys using reverse-polarity plasma torches with and the features of cutting thick sheets. The purpose of the work is to study the wear process of plasma torches operating on reverse polarity current when cutting thick rolled sheets of aluminum and titanium alloys. Research methods include optical and scanning electron microscopy, filming of the cutting process and visual inspection of plasma torch elements after receiving specimens. Results and discussion. The section shows the appearance of the main working elements of the plasma torch after cutting in various modes, which led to both stable and gradual wear and to catastrophic failure of the plasma torch. The results of structural studies of the main characteristic zones of nozzles and electrodes after cutting are presented. The studies carried out made it possible to establish the main reasons for the failure of the working elements reverse-polarity plasma torches. The causes of catastrophic failure of plasma torches include failure to maintain the gap between the nozzle and the electrode and melting of the channel of gas supply into the discharge chamber. The wear of nozzles and electrodes in a stable mode can be intensified due to abnormal operation of the starting arc, the presence of manufacturing inaccuracies and excess gas pressure. In conclusion, the main conclusions based on the results of the research are formulated. The process of wear of electrodes, nozzles and body elements of plasma torches during operation at high electric arc power values is described.

Development and characterization of atmospheric pressure gliding Arc plasma jet

In this work, we present the development and comprehensive characterization of an atmospheric pressure gliding arc plasma jet (GAPJ) operating in ambient air to generate non-thermal plasma. Through systematic investigation, the relationship between jet length and airflow rate indicates a positive correlation. Electrical and optical techniques are utilized to characterize the discharge, revealing an impact of applied voltage and gas flow rate on discharge parameters. Calculations are made for parameters such as electron density ((0.62−3.44)×1019) m −3, average power dissipation (9.85−40.50) W, and root mean square values of current and voltage. The impacts of applied voltages and gas flow rate on these parameters are also examined. Electron excitation temperature is determined using the Boltzmann plot method, yielding values within the range of (1.36−1.44) eV. Rotational and vibrational temperatures of discharge are analyzed, revealing values of (1373−2065) K and (2700−2405) K, respectively, under different operational conditions. The generated non-thermal plasma is confined to form a plasma plume although it consists of two diverging electrodes and offers promising applications for specified areas of sterilization and decontamination in the medical, pharmaceutical, and food processing industries.

Accurate comparison of the fracture toughness of ultra-thick polycrystalline diamond plates by ISO standard method

Due to the difficulty in preparing ultra thick diamonds, current research on the mechanical properties of diamonds mostly focuses on thin samples, which cannot represent the true mechanical properties. In this study, DC arc plasma jet chemical vapour deposition method was used to deposit ultra-thick diamond plate measuring Ø125 mm × 6.5 mm. The size of 18 mm × 4 mm × 3 mm sample were prepared. The samples with dimensions of 18 mm × 4 mm × 3 mm were prepared. For the first time, fracture toughness test samples meeting the ISO 15732 requirements were prepared by using the single-sided beam pre-crack method. The accurate fracture toughness of ultra-thick diamond with pre-crack was obtained using the three-point bending method, 6.5 MPa·m1/2. Samples with sharp or blunt notch by laser cutting were used for comparison. The sharp notch sample had a value similar to that of the pre-crack sample, 6.3 MPa·m1/2. The value of the blunt notch sample was relatively large, 7.5 MPa·m1/2. The effects of defects and grain size on fracture toughness and the reasons for the differences in test results for different notches were analyzed. Overall, obtaining accurate fracture toughness values of ultra-thick diamond by ISO standard is crucial for industrial applications.

Effect of fast frequency double pulse current on microstructural characteristics and mechanical properties of wire arc additively manufactured Ti-6Al-4V alloy

This study introduces an innovative technique known as fast-frequency double pulse wire arc metal additive manufacturing (FFDP-WAAM). This method employs periodic fluctuations in arc plasma and force to enhance the stirring effect within the molten pool, resulting in the fragmentation of β grains and the formation of finer prior-β grains. The microstructure primarily comprises α', attributed to the high cooling rates and minimal heat accumulation. Compared to the conventional gas tungsten arc welding-based WAAM (CGT-WAAM) process, FFDP-WAAM significantly reduces α-variant selection, thereby achieving a more uniform α phase orientation distribution. Additionally, ultrasonic vibration in the FFDP-WAAM process facilitates recrystallization and mitigates residual strain. The tensile strength and elongation of the FFDP-WAAM specimens reached 939.2 MPa and 9.0 %, respectively, whereas the CGT-WAAM specimens showed a lower tensile strength of 830 MPa and elongation of 9.2 %. The enhanced strength, fatigue life and microhardness of Ti-6Al-4V produced by FFDP-WAAM is ascribed to the refined grain-size distribution. Furthermore, the low Schmid factor (SF) distribution and the stable triangular structure of Category I α-clusters are anticipated to contribute to the increased strength of the FFDP-WAAM-fabricated wall.

Molecular dynamics simulation study of graphene synthesis by rotating arc plasma

The rotating arc plasma method, based on its unique characteristics, provides a simple, efficient, and catalyst-free approach for graphene material synthesis. This study employs molecular dynamics simulations to theoretically investigate the detailed growth process of graphene at the atomic scale using plasma. During the growth process, different radicals serve as dissociation precursors within the plasma. Simulation results indicate that the growth process of graphene clusters involves three stages: extension of carbon clusters, cyclization of carbon chains, and coalescence of clusters into sheets. Firstly, the precursor concentration affects the size of graphene clusters; increasing the precursor concentration enlarges the cluster size but also increases the likelihood of curling. Secondly, increasing the hydrogen content in the precursor can reduce the growth rate of clusters, decrease dangling bonds at the periphery of clusters, thereby slowing down cluster closure and maintaining a well-defined sheet structure. Lastly, appropriately elevating the simulation temperature can enhance the reaction rate during the simulation process without altering the reaction pathway. These research findings establish the foundation for understanding the growth mechanism of graphene.

Low-NOx thermal plasma torches: A renewable heat source for the electrified process industry

Industrial thermal plasma torches can heat a gas up to 5000–20,000 K, i.e., well above the temperature needed to replace the heat generated from the combustion of traditional fossil fuels (e.g., coal, oil, and natural gas) in large-scale process industry furnaces producing construction materials (e.g., iron, steel, lime, and cement). However, there is a risk for significant NOx emissions when air or N2 are used as plasma-forming gas since the temperature somewhere in the furnace always will be higher compared to the threshold NOx formation temperature of ∼1800 K. Torch NOx forms inside the high temperature region of the plasma torch (>5000 K) when air is used as gas. Process NOx forms instead when the hot gas (when air or nitrogen is used as plasma forming gas) from the plasma torch mixes with process air downstream the torch. By analysing the complex chemistry of both the torch- and process NOx formation with thermodynamic equilibrium and one-dimensional chemical kinetic calculations it was shown that adding H2 to the plasma-forming N2 gas significantly reduces the NOx emissions with more than 90 %. Verifying experiments with air, pure N2, and mixtures of H2 and N2 as plasma-forming gas were performed in a laboratory scale insulated laboratory furnace with different pre-heating temperatures of process air (293, 673, and 1073 K) which the plasma gas mixes with downstream the torch. Depending on the pre-heating temperature the NOx emissions were between 12,000–14,000 mg NO2/MJfuel when air was used as plasma forming gas. Substantial NOx emission reduction occurs both when N2 replaces air, where the NOx emissions was in the span of 8000–11,500 mg NO2/MJfuel and furthermore when H2 was mixed into the N2 gas stream. For the highest degree of H2 mixing (28.6 vol-%), the NOx emissions were between 450–1700 mg NO2/MJfuel depending on the pre-heat temperature of the process air, i.e., a reduction of 88–96 % and 85–94 %, respectively when air or N2 was used as plasma forming gas. The measured NOx emissions are then of the same order of magnitude as would be expected from the combustion of traditional fuels (coal, oil, biomass and pure H2). Finally, by analysing the aerodynamics in an axisymmetric furnace with an experimentally validated computational fluid dynamics (CFD) model using reduced chemistry for the NOx formation (19 species and 70 reactions), further guidelines into the process of NOx reduction from thermal plasma torches are given.

The Influence of Injection Mode and Spray Distance on Wear Resistance of Al2O3+13 wt.% TiO2 coatings

Abstract Atmospheric plasma spraying (APS) allows deposition of ceramic coatings on metallic substrate, significantly increasing the wear resistance of the component. Coating’s microstructure and consequently its properties, depend on heat treatment of the feedstock particles. This property can be controlled by process parameters, especially electric power and spray distance. On the other hand, some plasma torches allow introducing another variable, an injection mode, which could be realized in external or in internal way. In the presented research, wear resistance of Al2O3+13 wt.% TiO2 coatings deposited under various values of spray distance and different injection modes were examined using ASTM G-99 procedure. The impact of spraying parameters on the coating’s microstructure was established and connected to the functional properties of the manufactured deposits. Observed differences indicated influence of injection mode and spray distance value. Coatings deposited with internal feedstock injection exhibit lower porosity and slightly higher hardness than these made with external injection mode. In terms of wear resistance for both spray distance the wear factor was lower for internal injection system. Obtained results confirmed assumed thesis, that internal injection mode improves heat treatment and consequently ameliorate wear performance of plasma sprayed alumina-titania coatings.

Strategic selection of metal-cutting processes for thick steel plates using a hybrid decision methodology

Metal-cutting is indispensable in manufacturing, enabling precise component fabrication for industries like construction, automotive, aerospace, and shipbuilding, where accurate, efficient cutting of thick steel plates is crucial. This paper introduces a novel case study to strategically determine the optimal metal-cutting process for thick steel plates utilizing a hybrid MOORA-PSI approach. The use of the hybrid MOORA-PSI method simplifies decision-making by integrating weight assignment and ranking of alternatives. Five prominent metal-cutting processes, including oxygen flame, plasma arc, laser, wire EDM (wire electro-discharge machining), and abrasive water jet cutting, are commonly used for cutting thick steel plates, each with unique capabilities and limitations, and are considered potential alternatives. Eight evaluation criteria, capital cost, running cost, accuracy, edge quality, kerf width, maximum thickness, production flexibility, and production rate, are used to assess these metal-cutting alternatives. Wire EDM ranks as the optimal choice for cutting thick steel plates based on defined evaluation criteria, with laser cutting closely trailing, followed by oxygen flame, abrasive water jet, and plasma cutting successively. The results are validated by comparing them with those of other MCDM approaches and by conducting a Spearman’s rank correlation coefficient test, yielding consistent results. Additionally, sensitivity analysis, employing criteria weight exchange and dynamic variations in the decision-making matrix, further confirms the accuracy and reliability of the findings.

On-Line Analysis of Cigarette Smoke Based on Microwave Plasma Torch Mass Spectrometry.

Cigarette smoke contains a large number of chemicals, including both flavor components and harmful substances. The mainstream smoke (MSS) generated by smoking is directly inhaled by individuals, making it crucial to establish an effective method for smoke detection and analysis. One promising technique for analyzing smoke is MPT-MS (Microwave plasma torch mass spectrometry). This approach offers several advantages in accurately detecting the composition of cigarette smoke. By combining MPT-MS with a smoke pumping device, we can achieve real-time online detection of smoke components. We successfully detected 22 flavor compounds present in the smoke. These compounds contribute to the distinct taste of cigarettes. Moreover, we identified 2 polycyclic aromatic hydrocarbons (PAHs) in the smoke. PAHs are known carcinogens and are of great concern in terms of their potential health risks. The successful detection and identification of flavor compounds and PAHs using our method confirm the online detection capability of MPT-MS. This approach provides an efficient and reliable means for analyzing the complex composition of cigarette smoke. By utilizing MPT-MS, we can gain valuable insights into the chemical composition of cigarette smoke and can inform the development of strategies and policies aimed at reducing the harmful effects of smoking and protecting public health.

Basic model for calculating the macroscopic temperature of plasma plume and comparison with electron excitation temperature by optical spectroscopy method for non-transferred DC plasma torch

Basic model for calculating the macroscopic temperature of plasma plume and comparison with electron excitation temperature by optical spectroscopy method for non-transferred DC plasma torch

DFT Guided Design and Preparation of Quasi-Nanocrystalline Hf-La2O3 Cathode with Unprecedented Thermal Emission Performance.

With the guidance of density functional theory (DFT), a high-performance hafnium (Hf) cathode for an air/water vapor plasma torch is designed and the concepts and principles for high performance are elucidated. A quasi-nanocrystalline hexagonal close-packed (HCP) Hf-La2O3 cathode based on these design principles is successfully fabricated via a powder metallurgy route. Under identical voltage and temperature conditions, the thermal emission current density of this quasi-nanocrystalline Hf-La2O3 cathode is ≈20 times greater than that of conventional Hf cathodes. Additionally, its cathodic lifespan is significantly extended. Quasi-nanocrystalline Hf-La2O3 products are manufactured into cathode devices with standard dimensions. This fabrication process is straightforward, requires minimal doped oxides, and is cost-effective. Consequently, the approach offers substantial performance enhancements over traditional Hf melting methods without incurring significantly additional costs.

Experimental study of arc plasma energy deposition flow control on supersonic cavity combustor

Experimental study of arc plasma energy deposition flow control on supersonic cavity combustor

Optimization and Analysis of Dry Sliding Wear Behavior of AlCrTiSiN Coated SKD61 Steel Using Response Surface Methodology

The aim of this research is to investigate the wear behavior of SKD61 steel coated with AlCrTiSiN using the Filtered cathodic arc plasma deposition coating method while adhering to VDI 3198 standards for coating adhesion assessment. Dry sliding wear tests, conducted according to ASTM G133-05. The experiment is designed using response surface methodology (RSM) to determine the response parameter as the wear rate, with independent parameters of interest including load, sliding velocity, and sliding distance ranging from 5 to 11N, 0.1 to 0.2 m/s, and 250 to 550 m, respectively. Additionally, wear characteristics are analyzed using SEM-EDS analysis. The wear test results demonstrate that load had the most significant impact on the wear rate, followed by distance and speed, respectively. The target of achieving minimal wear rate was attained with a load of 5 N, a sliding velocity of 0.11 m/s, and a sliding distance of 550 m. Model significance testing revealed that the determination coefficient (R2) and adjusted determination coefficient values, indicating the accuracy of the model, were equal to 93.96% and 88.53%, respectively.