DC Plasma Spray Torch Research Articles

Control of the Arc Motion in DC Plasma Spray Torch with a Cascaded Anode

Two common concerns in DC plasma torches are stability of plasma jet and anode erosion. The challenge is how to get a stable plasma jet with minimal anode erosion. This study tackles this question by using either a swirling gas injection or an external axial magnetic field applied to the Oerlikon SinplexPro™ plasma torch. A 3-D, time-dependent MHD model of the plasma torch operation was used to predict the value of the external magnetic field and its effect on the heat flux to the anode and plasma jet stability. The special feature of the model is to couple the gas phase and electrodes that makes it possible to follow the anode temperature evolution. For specific operation conditions (anode of O9 mm, 500 A, Ar 60 NLPM), the model predicted that the maximal value of the azimuthal self-magnetic field inducted by the arc current was 0.055 T; it also showed that an external magnetic field of 0.05 to 0.1 T could make it possible to limit the anode erosion without noticeably disturbing the plasma jet issuing from the plasma torch. We expect this approach to help to better understand the arc behavior in commercial plasma torches and control anode erosion

Electric Arc Fluctuations in DC Plasma Spray Torch

Direct current plasma torches for plasma spraying applications generate electric arc instabilities. The resulting fluctuations of input electrical power hamper a proper control of heat and momentum transfers to materials for coating deposition. This paper gives an overview of major issues about arc instabilities in conventional DC plasma torches. Evidences of arc fluctuations and their consequences on plasma properties and on material treatments are illustrated. Driving forces applied to the arc creating its motion are described and emphasis is put on the restrike mode that depends on the arc reattachment and the boundary layer properties around the arc column. Besides the arc root shown as a key region of instability, the Helmholtz oscillation is also described and accounts for the whole plasma torch domain that can generate pressure fluctuations coupled with voltage ones.

Analytical interpretation of arc instabilities in a DC plasma spray torch: the role of pressure

Arc instabilities in a plasma spray torch are investigated experimentally and theoretically thanks to a linear simplified analytical model. The different parameters that determine the useful properties of the plasma jet at the torch exit, such as specific enthalpy and speed, but also pressure inside the torch and time variations of the flow rate are studied. The work is particularly focused on the link between the recorded arc voltage and the pressure in the cathode cavity. A frequency analysis of the recorded voltage and pressure allows the separation of different contributions following their spectral characteristics and highlights a resonance effect due to Helmholtz oscillations; these oscillations are responsible for the large amplitude fluctuations of all the parameters investigated. The influence of heat transfer, friction forces and residence time of the plasma in the nozzle are taken into account, thanks to different characteristics’ times. The volume of the cathode cavity in which the cold gas is stored before entering the arc region appears to be of prime importance for the dynamics of instabilities, particularly for the non-intuitive effect that induces flow-rate fluctuations in spite of the fact that the torch is fed at a constant flow rate.

Arc-Cathode Coupling in the Modeling of a Conventional DC Plasma Spray Torch

The plasma torch is the basis of the plasma spray process and understanding of the electric arc dynamics within the plasma torch is necessary for better control of torch and process instabilities. Numerical simulation is a useful tool for investigating the effect of the torch geometry and operating parameters on the electric arc characteristics provided that the model of arc dynamics is reliable and the boundary conditions of the computational domain are well founded. However, such a model should also address the intricate transient and 3D interactions between the electrically conducting fluid and electromagnetic, thermal, and acoustics phenomena. Especially, the description of the electrode regions where the electric arc connects with solid material is an important part of a realistic model of the plasma torch operation as the properties of electric arcs at atmospheric pressure depend not only on the arc plasma medium, but also on the electrodes. This paper describes the 3D and time-dependent numerical simulation of a plasma arc and is focused on the cathode boundary conditions. This model was used to investigate the differences in arc characteristics when the cathode is included into the numerical domain and coupled with the arc. The magnetic and thermal coupling between the cathode and arc made it possible to get rid of the current density boundary condition at the cathode tip that is delicate to predetermine. It also allowed a better prediction of the cathode flow jet generated by the pumping action induced by the interaction of the self-magnetic field with the electric current and so it allowed a better description of the dynamics of arc. It should be a necessary step in the development of a fully predictive model of DC plasma torch operation.

Resonant mode for a dc plasma spray torch by means of pressure–voltage coupling: application to synchronized liquid injection

Electric arc instabilities in dc plasma torches result in non-homogeneous treatment of nanosized solid particles injected into the plasma jets. In the particular case of suspension plasma spraying, large discrepancies in the particles trajectories and thermal histories make the control of coating properties more difficult to achieve. In this paper, a new approach of arc dynamics highlights the existence of different resonant modes and the possibility of their coupling. This study leads us to design a special plasma torch working in a very regular pulsed regime. Then, an innovative injection system based on the drop-on-demand method synchronized with the plasma oscillations is presented as an efficient method to control the dynamics of plasma/particles interactions.

Solution precursor plasma deposition of nanostructured ZnO coatings

Zinc oxide (ZnO) is a wide band gap semiconducting material that has various applications including optical, electronic, biomedical and corrosion protection. It is usually synthesized via processing routes, such as vapor deposition techniques, sol–gel, spray pyrolysis and thermal spray of pre-synthesized ZnO powders. Cheaper and faster synthesis techniques are of technological importance due to increased demand in alternative energy applications. Here, we report synthesis of nanostructured ZnO coatings directly from a solution precursor in a single step using plasma spray technique. Nanostructured ZnO coatings were deposited from the solution precursor prepared using zinc acetate and water/isopropanol. An axial liquid atomizer was employed in a DC plasma spray torch to create fine droplets of precursor for faster thermal treatment in the plasma plume to form ZnO. Microstructures of coatings revealed ultrafine particulate agglomerates. X-ray diffraction confirmed polycrystalline nature and hexagonal Wurtzite crystal structure of the coatings. Transmission electron microscopy studies showed fine grains in the range of 10–40 nm. Observed optical transmittance (∼65–80%) and reflectivity (∼65–70%) in the visible spectrum, and electrical resistivity (48.5–50.1 mΩ cm) of ZnO coatings are attributed to ultrafine particulate morphology of the coatings.

Effects of plasma parameters and collection region on synthesis of iron and nickel aluminide composite particles during thermal plasma processing

Iron and Nickel aluminide composite particles were synthesized by non-transferred DC plasma spray torch at atmospheric pressure. Irregular shaped ball milled, micron sized powders were fed in to the plasma flame using argon as carrier gas. The particles got molten and vaporized. The vapour condensed on the walls of the reaction chamber and nanoparticles were formed. The molten particles got spheroidized due to surface tension forces. Powders as formed were collected in the plasma reactor at three different sections (Section A, B and C). These powder particles were characterized by X-ray diffraction (XRD) and scanning electron microscopy (SEM). The particle size and morphology of the composite particles strongly varied depending on the processing parameters and collection region. The results were discussed.

Numerical and experimental studies on DC plasma spray torch

One of the challenging problems in the plasma spray technique is reproducibility of the coating quality. This problem is mainly associated with arc fluctuations, which affect the plasma jet temperature and velocity, inside the plasma torch. In this study, 3D numerical models are developed to study the arc behavior inside the torch and effect of arc fluctuations on plasma jet temperature and velocity. Plasma arc is simulated for different operating parameters. Different arc sizes are predicted by using thermo-dynamical principle of minimum entropy production for given torch power. The influence of arc current and gas flow rate on the Ar–N 2 plasma arc characteristics, plasma jet and torch efficiency is presented. Predicted torch efficiencies and arc voltages are comparable with measurements. At the nozzle exit, velocity shows stronger three-dimensional effect than temperature. Plasma jets are simulated using different nozzle exit profiles obtained from the plasma arc model and their temperature and velocity distributions are clarified.

Synthesis of nanophase alumina, and spheroidization of alumina particles, and phase transition studies through DC thermal plasma processing

Using a non-transferred DC plasma spray torch, nanosized alumina particles were synthesized from micron-sized aluminium particles. Irregular-shaped micron-sized alumina particles were spheroidized using the plasma spray torch. The synthesized powder particles were characterized by field emission scanning electron microscopy (FESEM), X-ray diffraction (XRD), energy dispersive X-ray (EDX) analysis, Fourier transform infra-red (FT-IR) spectroscopy and photoluminescence (PL) spectroscopy. The synthesized alumina nanoparticles appear spherical in shape, but mostly agglomerated in the size range 30–75 nm. It was identified that the main phase is γ-alumina with a small amount of δ-alumina. In the spheroidized alumina particles, the main phase is α-alumina with a small amount of γ-alumina. The mechanism of formation of alumina and its phase change are explained in detail.

Synthesis and characterization of iron aluminide nanoparticles by DC thermal plasma jet

Intermetallic iron aluminide alloy nanoparticles were synthesized by non-transferred DC plasma spray torch at atmospheric pressure. These powder particles were characterized by vibrating sample magnetometer (VSM), X-ray diffraction (XRD), environmental scanning electron microscopy (ESEM), laser scattering particle size distribution analyzer, energy dispersive X-ray spectra (EDX) and thermo gravimetric-differential thermal analysis (TG/DTA) studies and the results are discussed. Commercially available iron and aluminium powders in the size range between 40 and 100 μm were ball milled with suitable ratio (Fe-85% and Al-15%) by weight to form a iron–aluminium blende; this was used as feed stock to synthesize iron aluminide nanoparticles. These nanoparticles particles were spherical in shape and black in colour, with the size range between 30 and 70 nm observed by ESEM. It is seen that the powders processed at higher power levels (15.3 kW) have more number of single spherical nanoparticles than powders processed at lower power levels (9.8 kW). The formation of iron aluminide nanoparticles is confirmed by XRD analysis and an exothermic reaction by DTA studies.

Formation of doughnut-shaped aluminium particles in a DC non-transferred argon thermal plasma jet

In this paper, aluminium macro powders in the size range between 300 and 500 μm are processed by thermal plasma processing. A 40 kW DC non-transferred DC plasma spray torch was used to get the macro powders. The morphology and the size of the powders are discussed and the results are reported. The powders produced are doughnut shaped. The size ranges between 300 and 500 μm. The macro particle size is estimated theoretically and found to be in good agreement with experimental results. The error percentage between theoretical estimation and experimental result is about 25%. The pressure inside the particle is estimated. The pressure gradient develops the indentation on the powder surface which seems to be doughnut.

Modeling the Restrike Mode Operation of a DC Plasma Spray Torch

A key aspect of the operation of conventional non-transferred direct current (dc) plasma torches is the random motion of the arc inside the nozzle. Various plasma gun designs have been developed to limit the arc fluctuations without increasing the heat load to the anode wall that results in surface erosion and anode wear. However, construction of these plasma torches is highly complex, while the conventional dc plasma torch consists of a small number of elements and is simple to manufacture and maintain. A better understanding of the behavior of the arc-anode attachment and how it depends on operating conditions may help in the design and operation of conventional plasma torches so that the fluctuation of the time-voltage, and therefore the time-enthalpy variation, is as low as possible with a fluctuation frequency adapted to the time characteristic of the powder particles in the plasma jet. This study deals with a three-dimensional (3D) timedependent modeling of the arc and plasma generation in such a torch operating under the so-called “restrike” mode. The latter is characterized by rather large voltage fluctuations, corresponding to a broad range of conditions used in the manufacturing of plasma coatings. The mathematical model is based on the simultaneous solution of the conservation equations of mass, momentum, energy, electric current, and electromagnetic equations. These make it possible to predict the effect of operating parameters of the plasma torch on the motion of the anode root attachment over the anode surface and the time-evolution of arc voltage and flow fields in the nozzle.

A simplified analytical model for dc plasma spray torch: influence of gas properties and experimental conditions

A simplified analytical model is proposed to evaluate some characteristics of the arc jet generated with a dc plasma torch, in the restricted area of atmospheric plasma spraying conditions. The plasma inside the anode nozzle is considered as stationary and is divided into the arc column and a surrounding cold layer which electrically insulates the plasma from the nozzle wall. Radiation and processes related to the arc attachment at the electrodes are not explicitly taken into account. Heat conduction is evaluated by using Kirchoff's potential, which is described, as it is done also for the electrical conductivity, as a function of the gas specific enthalpy instead of temperature. The model is used to calculate the specific enthalpy radial distribution. From that, and by introducing a mean isentropic coefficient, it is possible to calculate the axial velocity of the plasma jet at the nozzle exit and to evaluate the different pressure contributions. The comparison between predicted and previously measured plasma jet velocities shows good agreement for various experimental conditions.

NUMERICAL MODELING OF A DC NON-TRANSFERRED PLASMA TORCH: MOVEMENT OF THE ARC ANODE ATTACHMENT AND RESULTING ANODE EROSION

This paper describes a 3-D transient modeling of a DC plasma spray torch. The model of the arc column and its attachment on the anode wall is based on the simultaneous solutions of the conservation equations of mass, momentum, energy and the electromagnetism equations. It makes it possible to predict the motion of the anode attachment root on the anode surface as well as the heat load input to the anode surface at the spot location. The heat flux to anode is afterwards used as an input data for a 1-D enthalpy formulation model of anode heating that predicts the time-evolution of the thickness of the liquid layer on the surface at the anode spot and the quantity of vaporized material.

Electrothermal efficiency, temperature and thermal conductivity of plasma jet in a DC plasma spray torch

A study was made to evaluate the electrothermal efficiency of a DC arc plasma torch and temperature and thermal conductivity of plasma jet in the torch. The torch was operated at power levels from 4 to 20 kW in non-transferred arc mode. The effect of nitrogen in combination with argon as plasma gas on the above properties was investigated. Calculations were made from experimental data. The electrothermal efficiency increased significantly with increase in nitrogen content. The plasma jet temperature and thermal conductivity exhibited a decrease with increase in nitrogen content. The experiment was done at different total gas flow rates. The results are explained on the basis of dissociation energy of nitrogen molecules and plasma jet energy loss to the cathode, anode and the walls of the torch

Current-voltage characteristics of a non-transferred plasma spray torch

I–V characteristics of a non-transferred DC plasma spray torch operating on argon and argon + nitrogen mixtures are reported. Arc voltage is decreased with increase in arc current and increased with increase in electrode gap. Arc power is higher at higher percentage of nitrogen in argon. Nottingham co-efficients were calculated using numerical method.

Characterization of a spray torch and analysis of process parameters

Anode for a non-transferred DC plasma spray torch was designed to improve electrothermal efficiency. A theoretical calculation was made for the electrothermal efficiency in a DC plasma torch operating with argon at atmospheric pressure with power level in the range of 5.2–20 kW using energy balance equations. ANOVA for the two level factorial design was done. Plasma gas flow rate, current intensity, nozzle diameter and length were found to influence the efficiency. The efficiency was found to decrease with increase in current intensity and nozzle length and to increase with increase in nozzle diameter and gas flow rate. The overall energy balance calculations showed that the heat transfer to the plasma-forming gas decreases with increase in arc current and the same was more significant at higher flow rates. Plasma jet velocity for different flow rates, input to the torch and nozzle dimensions was calculated from the gas enthalpy. It was found that the velocity increased with increase in the power input to the torch and gas flow rate and decreased with increase in nozzle length and diameter. The current–voltage characteristics of the torch operating with argon gas were studied for different gas flow rates. The Nottingham coefficients were calculated using least – square method.

Velocity Measurements for Arc Jets Produced by a DC Plasma Spray Torch

An optical method was used to determine the axial velocity of plasma jets produced by a DC plasma spray torch. Different experimental conditions were tested in order to systematically study the influence of the working parameters on the plasma velocity. In this way, the arc current ranged between 200 and 600 A, the gas flow rate between 30 and 80 slm, and the internal nozzle diameter between 6 and 10 mm; the plasma gases were either an Ar–H 2 mixture or N 2 . Rather well defined tendencies were observed and at the same time it appeared that the arc stability greatly influenced the fluctuations of the velocity.

Characterization of DC plasma spray torch using energy balance technique and thermo-fluid dynamical consideration

Abstract A non-transferred plasma torch is characterized. Electrothermal efficiency of the plasma torch and the stagnation enthalpy of the plasma jet were calculated using the energy balance technique. Argon and argon + 10% nitrogen mixture were the plasma forming gases. Average electrical conductivity of the plasma jet at the nozzle was calculated from the arc characteristics. The temperature, velocity, thrust, density and the degree of ionization of the plasma jet were also calculated from the thermofluid dynamical method. In addition the heat transfer from plasma jet to the solid wall was also considered. In all the calculations the experimental values of the parameters were used. The calculated efficiency ranged from 59-65%. Efficiency was found to increase with addition of nitrogen. The temperature and the degree of ionization were found to be in the range 1400-7500 °K and 0.4-5 × 10−3 respectively. The results are explained and discussed qualitatively.

Velocity measurement of dc plasma jets based on arc root fluctuations

The axial component of the radial velocity distribution of a plasma flow generated by a dc plasma spray torch was measured by using a nonintrusive optical method, based on the propagation of the plasma jet luminosity fluctuations. In contrast to the simplicity of the experimental set-up, a special effort was made in the data processing, namely by using numerical techniques defined in the context of signal theory. Both centerline and radial profiles of the axial velocity were obtained for pure Ar and Ar−H2 plasma flows. These experimental results were satisfactorily validated by calculating enthalpy and mass balances.