Arc Plasma Research Articles

Investigations of the Interface Design of Polyetheretherketone Filament Yarn Considering Plasma Torch Treatment

Taking advantage of its high-temperature resistance and elongation properties, conductive-coated polyetheretherketone (PEEK) filament yarn can be used as a textile-based electroconductive functional element, in particular as a strain sensor. This study describes the development of electrical conductivity on an inert PEEK filament surface by the deposition of metallic nickel (Ni) layers via an electroless galvanic plating process. To enhance the adhesion properties of the nickel layer, both PEEK multifilament and monofilament yarn surfaces were metalized by plasma torch pretreatment, followed by nickel plating. Electrical characterizations indicate the potential of nickel-coated PEEK for structural monitoring in textile-reinforced composites. In addition, surface energy measurements before and after plasma torch pretreatment, surface morphology, nickel layer thickness, chemical structure changes, and mechanical properties were analyzed and compared with untreated PEEK. The thickness of the Ni layer was measured and showed an average thickness of 1.25 µm for the multifilament yarn and 3.36 µm for the monofilament yarn. FTIR analysis confirmed the presence of new functional groups on the PEEK surface after plasma torch pretreatment, indicating a successful modification of the surface chemistry. Mechanical testing showed an increase in tensile strength after plasma torch pretreatment but a decrease after nickel plating. In conclusion, this study successfully developed conductive PEEK yarns through plasma torch pretreatment and nickel plating.

The Gasification and Pyrolysis of Biomass Using a Plasma System

This research paper analyzes the use of plasma technology to process biomass in the form of dried, mixed animal manure (dung containing 30% moisture). The irrational use of manure as well as huge quantities of it can negatively impact the environment. In comparison to biomass fermentation, the plasma processing of manure can greatly enhance the production of fuel gas, primarily synthesis gas (CO + H2). The organic part of dung, including the moisture, is represented by carbon, hydrogen, and oxygen with a total concentration of 95.21%, while the mineral part is only 4.79%. A numerical analysis of dung plasma gasification and pyrolysis was conducted using the thermodynamic code TERRA. For 300–3000 K and 0.1 MPa pressure, the dung gasification and pyrolysis were calculated with 100% dung + 25% air and 100% dung + 25% nitrogen, respectively. Calculations were performed to determine the specific energy consumption of the process, the composition of the products of gasification, and the extent of the carbon gasification. At 1500 K, the dung gasification and pyrolysis consumed 1.28 and 1.33 kWh/kg of specific energy, respectively. A direct-current plasma torch with a power rating of 70 kW and a plasma reactor with a dung processing capacity of 50 kg/h were used for the dung processing experiments. The plasma reactor consumed 1.5 and 1.4 kWh/kg when pyrolyzing and gasifying the dung. A maximum temperature of 1887 K was reached in the reactor. The plasma pyrolysis of dung and the plasma–air gasification of dung produced gases with specific heats of combustion of 10,500 and 10,340 kJ/kg, respectively. Calculations and experiments on dung plasma processing showed satisfactory agreement. In this research, exergy analysis was used to quantify the efficiency of the plasma gasification of biomass. One of the research tasks was to develop a methodology and establish standards for the further standardization of monitoring the toxic emissions of dioxins, furans, and Benzo[a]pyrene.

Effect of Plasma Treatment on Self-Cleaning Features of Acrylic Paint/TiO2-Coated Surfaces for Environmental Pollutant Removal

This study investigates the characterization and performance of self-cleaning TiO2 surfaces synthesized through a one-step preparation process, followed by enhancement via plasma treatment. The process involved coating aluminum foil with an acrylic paint mixture containing nanoparticles of different mass compositions and subsequent plasma treatment using a continuous plasma arc. Scanning electron microscopy revealed the morphology of the treated surfaces, showing an increase in surface area of plasma-treated materials. Energy-dispersive X-ray spectroscopy revealed changes in oxygen and titanium in acrylic paint/TiO2 surfaces as the TiO2 content increased, indicating successful TiO2 incorporation. Raman spectroscopy showed that the bulk structure of self-cleaning acrylic paints is mainly preserved after plasma treatment. Alternating current impedance spectroscopy assessed that plasma treatment reduced agglomeration and increased active sites, especially for the acrylic paint/TiO2 surfaces with 0.5 mg/cm3 TiO2. The contact angle measurements indicated that plasma treatment enhanced the superhydrophobic characteristics and potential self-cleaning abilities of produced acrylic paint/TiO2 surfaces. The efficacy of these plasma-treated surfaces in self-cleaning was evaluated by testing their performance against puddle sediment and automotive oil samples. The study demonstrated that plasma treatment positively impacted the self-cleaning ability of the acrylic paint/TiO2 surfaces, particularly those with 0.5 mg/cm3 TiO2. This enhancement was attributed to the formation of functional groups, improved water repellency, and possible increases in surface area, which collectively contribute to the sustainable self-cleaning properties of the treated surfaces.

Study on Characterization of SrO Aerosols Generated by Optimized Thermal Plasma Torch Aerosol Generator

AbstractPlasma Torch Aerosol Generation System (PTAGS) has been employed to generate nano aerosols with desirable characteristics. The operational parameters of PTAGS installed in the aerosol test facility have been optimized, and aerosols are generated using non-radioactive SrO2 powder. The current-voltage characteristics, electro-thermal efficiency and torch power are studied as a function of the flow rate of the plasma-generating gas (mixture of argon and nitrogen) and the arc current of the plasma torch. The relation of arc characteristics is determined using the Nottingham formulation. Based on this, torch parameters evolved and optimized as 20 kW power, 70% electro-thermal efficiency, 25 L min− 1 flow rate of plasma forming gas, 5 mg min− 1 powder feed rate and for 4–5 min torch operation towards the generation of SrO nano aerosols to achieve 1012 m− 3 and ~ 25 mg m− 3 for the count and mass concentration of aerosol respectively. The initial size distribution of the aerosols is in the few tens of nanometre range (10–40 nm) with a mean diameter of 26 nm (σg = 1.45). Scanning Electron Microscope and Energy dispersive X-ray analysis revealed that the morphology of nano aerosols was nearly spherical and the formation of SrO nanoparticles. A set of PTAGS operational parameters has been standardized to perform further experiments related to reactor safety analysis. PTAGS shall be tuned for aerosol generation in a large facility to achieve the characteristics equivalent to reactor accidental conditions.

Structure and properties of the boride layer of steel using the plasma alloying method

Boration is one of the promising methods for increasing surface hardness and wear resistance, resistance to oxidation and corrosion of mechanical engineering parts. The diffusion saturation process is characterized by a long duration, as well as a shallow depth of the hardened layer. The use of concentrated heating sources can solve these problems. Among the methods of high-energy exposure, the technology of plasma surface alloying should be highlighted. In this paper, the study of the microstructure and properties of the boride layer obtained on steel by plasma alloying is carried out. It is noted that the boron-doped layer has a heterogeneous structure and high hardness. It is noted that the layer obtained after alloying with a current of 120 A has the highest microhardness value and amounts to 859–1265 HV. With an increase in current to 140 A, the microhardness of the alloyed layer decreases and amounts to 761–1048 HV. Increasing the current to 160 A leads to a significant decrease in the microhardness of the surface layer and it is 452–747 HV. It is known that the volume of iron boride fractions determines the degree of hardening of the steel surface. An increase in the plasma arc current leads to a decrease in the proportion of primary borides in the surface layer after alloying, and therefore leads to a decrease in microhardness. The alloyed layer has characteristic zones: hypereutectic, eutectic and hypoeutectic. An increase in current leads to a significant change in the microstructure of the surface layer and a decrease in the microhardness of the alloyed layer. The surface layer after plasma alloying with a current of 120 A has the highest microhardness (1265 HV). It has been established that it is possible to obtain a boride layer using the technology of plasma surface doping with boron. After processing, the alloyed layer is characterized by a heterogeneous structure and has high hardness.

Influence of Plasma Arc Current and Gas Flow on the Structural and Tribological Properties of TiN Coatings Obtained by Plasma Spraying

This study investigates the development of TiN-based coatings using plasma spraying technology, focusing on how plasma arc current and working gas flow rate affect the coatings’ structural-phase composition and mechanical–tribological properties. The research highlights the potential and effectiveness of plasma spraying for TiN coatings. Results from scanning electron microscopy and nanoindentation tests show that the TiN coatings have a dense microstructure with strong adhesion. Tribological testing demonstrated that coatings deposited at a 250 A arc current displayed the lowest coefficient of dry friction and the lowest porosity (2.13%) compared to those deposited at 350 A and 450 A arc currents, which exhibited higher porosity (up to 10.45%).

Microwave plasma torch desorption ionization mass spectrometry for chemical characterization of aromatic secondary organic aerosol

Benzene and toluene, primarily emitted from vehicle exhaust, are common volatile organic compounds (VOCs). These aromatic compounds in the atmosphere undergo further photooxidation to form secondary organic aerosol (SOA), which are a primary factor in haze weather. Aromatic SOA is more difficult to detect by traditional detection methods. Microwave plasma torch (MPT) is an ambient ionization source based on microwave plasma developed in recent years. Herein, a microwave plasma torch desorption ionization high-resolution mass spectrometry (MPT-HRMS) technique was designed for the direct analysis of aromatic SOA in the environment. For environmental haze samples, no pretreatment is required, and over twenty types of aromatic hydrocarbon derivatives or oxidation products can be detected in situ using MPT-HRMS. The possible mechanisms underlying the formation of aromatic SOA were investigated. MPT-HRMS is a powerful technical tool for rapidly tracking non-targeted aromatic SOA and their transformations in the environment. This contributes to an in-depth understanding of the formation mechanisms of SOA and their impact on air pollution.

Development of Numerical Analysis Method for Cathode Sheath Considering Electron Emission From Cathode in Vacuum Arc

ABSTRACTIt is imperative to develop the simulation of vacuum arcs as a tool to aid electrode design in vacuum circuit breakers. Although the development of electromagnetic thermo‐fluid simulations for vacuum arcs has been reported, most of them do not take cathode sheath phenomena into account and have not been able to reproduce vacuum arc phenomena, especially cathode spots. As the first step, the cathode sheath voltage, cathode surface electric field, and temperature and field (T‐F) electron emission current were analyzed numerically on the basis of the space charge in the cathode sheath. In this study, the cathode sheath was assumed to exist when the charge density induced on the cathode surface is positive, and the temperature and density of vacuum arc plasma and cathode temperature, which are physical quantities obtained by electromagnetic thermo‐fluid simulation, were used as parameters of the analysis. As a result, the cathode sheath voltage, electric field, and electron emission current density can be calculated from the vacuum arc plasma temperature, density, and cathode temperature. Numerical results show that the electron emission current density has a dominant effect on the presence or absence of the cathode sheath.

Effects of Nitrogen on Microstructure and Properties of SDSS 2507 Weld Joints by Gas Focusing Plasma Arc Welding

Regulating the phase ratio between austenite and ferrite in welded joints is crucial for welding super duplex stainless steel. Nitrogen plays a significant role in maintaining an optimal phase ratio. In this study, the focusing gas channel of gas-focused plasma arc welding was utilized to introduce nitrogen into the arc plasma, which was then transferred to the weld pool. Experiments with and without nitrogen addition were designed and conducted to examine the effects of nitrogen on the microstructure and properties of SDSS 2507 weld joints. The results show that nitrogen addition increased the austenite content in the weld metal from 22.2% to 40.2%. Nitrogen also altered the microstructure of the austenite, changing it from thin grain boundary austenite and small intragranular austenite to a large volume of coarse, side-plate Widmanstätten austenite. The ferrite in the weld metal exhibited a preferred orientation during growth, while the austenite showed a disordered orientation. Additionally, the maximum texture intensity of the ferrite decreased with nitrogen addition. Nitrogen addition led to an increase in the microhardness of the austenite in the weld metal, attributed to the solid solution strengthening effect of nitrogen and increased dislocation tangling, while it decreased the microhardness of the ferrite. This study enhances the welding theory of 2507 super duplex stainless steel and guides the practical application of gas-focused plasma arc welding for 2507 super duplex stainless steel.

A collisional-radiative model for atmospheric-pressure low-temperature air discharges

Plasma-assisted combustion technology has been a hot spot in aero-engines and scramjet-engines. The electron density is a key discharge parameter related to the active-particle density. The latter has been considered playing an important role in the above applications by the kinetic effect. In this work, an atmospheric pressure air plasma collisional-radiative model considering the excited states of atomic nitrogen and oxygen is built based on previous widely kinetic investigations of molecules and radicals, as well as their excited states. The excited states, especially the atomic nitrogen and oxygen states were less investigated in previous works. The emission intensity distributions from the model have a good agreement with those measured in the glide arc plasma with two discharge modes, as well as the microwave plasma. Based on the kinetics of molecular and atomic emitting states, the line-ratio method is presented to determine the electron density. The N2(337 nm) / O(844 nm) and N2(337 nm) / NO(γ) line ratios are used for the glide arc plasma and microwave plasma torch, respectively. Besides, the kinetics of the excited states involved with two line-ratios are also investigated in the two types of discharges. Combined with the atmospheric pressure actinometry method, the kinetic effect of the plasma-assisted combustion can be revealed quantitatively in the future.

Abatement of Volatile Organic Compounds (VOCs) and Fluorine gases by a Microwave Plasma Torch (MPT)

The use of microwave plasma torch (MPT) in the abatement of potent greenhouse and fluorinated (F-gases) gases is crucial due to their high global warming potential. The purpose of this study was the abatement of volatile organic compounds (VOCs) and carbon tetrafluoride (CF4) using specifically designed reverse vortex flow reactor (RVR) and pillar of fire reactor (POF). The RVR has properties that are crucial for their synergistic effects with the MPT, and the POF configurations showed high-efficiency combustion due to plasma radicals and a large contact area with the MPT. The study used Aspen Plus and COMSOL software to analyse the mass balance involved in the thermal decomposition of isopropyl alcohol (C₃H₈O) and CF4 and to design the RVR and POF reactors. Using MPT without hydrocarbon fuel, low-concentration C₃H₈O and CF4 were successfully destroyed in high-flow streams. The experiment on C₃H₈O showed that using a plasma power of 2kW and 1 cubic meter per minute (CMM) of bulk gas, a destruction removal efficiency (DRE) of 95% was achieved for a polluted C₃H₈O of 410 ppm. In a second experiment, a DRE of 94% was achieved for a polluted C₃H₈O of 370 ppm. The first CF4 experiment achieved a DRE of 93.3% with a 7kW plasma power and 1 CMM bulk gas polluted at 285 ppm. In the second experiment, the presence of highly reactive hydroxyl radicals (OH⁎) in steam plasma improved the DRE to 99.8% at 7kW plasma power and 100 LPM bulk polluted at 180 ppm.

Decay characteristic of gas arc in C4F7N/N2 and C4F7N/CO2 gas mixture by Thomson scattering

Abstract C4F7N/N2 and C4F7N/CO2 gas mixtures are considered potential alternative gases to SF6, and it is of particular significance to investigate the plasma decay process in these mixtures for evaluating their circuit breaker breaking performance. To comprehend the decay process of electron density(ne) in arc plasma within C4F7N/N2 and C4F7N/CO2 gas mixtures, an arc-generating circuit and a Thomson scattering experiment platform were established. Through coherent Thomson scattering diagnosis of gas arc plasma under various gas mixture conditions, a series of electron density results over time and space were obtained. The findings suggest that the initial electron density of the arc plasma diminishes with an increase in the proportion of C4F7N, and electron density decay is further accelerated as the proportion of C4F7N increases. Moreover, it was observed that the electron density decay rate is higher in the C4F7N/N2 mixture compared to the C4F7N/CO2 mixture. Notably, the electron decay rate in a 50% C4F7N/N2 mixture closely resembles that observed in pure SF6.

A Review of Welding Process for UNS S32750 Super Duplex Stainless Steel

Super duplex stainless steel UNS S32750 is widely used in marine industries, pulp and paper industries, and the offshore oil and gas industry. Welding manufacturing is one of the main manufacturing processes to make material into products in the above fields. It is of great importance to obtain high-quality welded UNS S32750 joints. The austenite content and ferrite content in UNS S32750 play an important role in determining UNS S32750 properties such as mechanical properties and corrosion resistance. However, the phase proportion between the ferrite phase and austenite phase in the welded joint will be changed during welding. Lots of research has been done on how to weld UNS S32750 and how to obtain welded joints with good quality. In this work, the recent studies on welding UNS S32750 are categorized based on the welding process. The welding process for UNS S32750 will be classified as gas tungsten arc welding, submerged arc welding, plasma arc welding, laser beam welding, electron beam welding, friction stir welding, and laser-MIG hybrid welding, and each will be reviewed in turn. The microstructure and properties of the joints welded using different welding processes will also be discussed. The critical challenge of balancing the two phases of austenite and ferrite in UNS S32750 welded joints will be discussed. This review about the welding process for UNS S32750 will provide people in the welding field with some advice on welding UNS S32750 super duplex stainless steel.

Ремонт деталей авіаційних двигунів із жароміцних нікелевих сплавів із застосуванням адитивних плазмових технологій

In order to improve the maintainability of aircraft engine parts, the article examined the use of additive technologies in repairs. The article establishes that the use of additive technologies by the method of plasma surfacing in the repair of aircraft engine parts, such as turbine blades, sealing discs, NA parts, is very promising and will significantly increase the percentage of parts and assemblies restored after operation, which have a significant area of damage. Turbine blades are made of nickel heat-resistant alloys with a polycrystalline structure (ЖС6К-ВИ, ЖС6У-ВИ), or from alloys with directional crystallization (ЖС32-ВИ, ЖС26-ВИ). After operating for more than 6 thousand hours, in addition to the operational wear of the ends and side walls of the shroud flanges, thermal fatigue cracks up to 6 mm deep are observed on the blades received for repair. The technology of argon-arc surfacing and the surfacing materials existing for this process do not provide the heat-resistant properties of the restored surface necessary for the operation of the blades. The solution to the problem was achieved through the use of a compressed arc source with precision adjustment of the welding current and mechanization of the supply of filler material (powder), which would make it possible to surfacing with a limited penetration depth and, accordingly, mixing the deposited material with the base metal. The developed technology made it possible to restore damaged sections of blades after operation (shroud flanges, labyrinth scallops, z-shaped profiles and airfoil ends) on heat-resistant alloys using filler material equal to the strength of the base metal. For this process, powders of nickel and cobalt alloys with a fraction of +63...-160 microns are used, obtained by atomization with a jet of inert gas (argon). The main powders used are ЖС32-ВИ, ЖС6К-ВИ, В3К, Stellite 12, Stellite 6, ХТН61. Disc material – ЭП742-ИД. Working medium, air, oil and combustion products. The maximum heating temperature of labyrinth scallops is up to 680 ºC at a maximum medium pressure of up to 1.47 MPa. The maximum peripheral speed of the scallop end is 251 m/s. Material of seal mating parts ЭИ435 (cell δ = 0,1 mm). When developing the technology, the successful experience of restoring labyrinthine scallops of turbine blades was taken into account. The restoration of the labyrinthine ridges of the disk was carried out using a compressed arc source with precision control of the welding current and a robotic installation, which included a robot for moving the plasma torch and a manipulator for rotating the disk. This made it possible to carry out surfacing with a limited penetration depth and obtain a uniformly directed bead over the entire diameter of the disk. Testing of the restored disk in order to verify its performance was carried out as part of a run-in aircraft engine. To do this, after the next assembly of the run-in engine, the disk was installed in the MPT rotor. The test was carried out in 5 cycles, the duration of each cycle was 15 hours. No wear of the labyrinth ridges or cracks was detected. The functionality of the restored disk has been confirmed. NA parts are made of heat-resistant, low-aging, high-chromium nickel-based alloy ЭП648-ВИ. They operate in hot engine conditions at temperatures up to 900'C. As a result of operation, both end surfaces and flat surfaces in the tract area are subject to wear. To restore parts of the NA, the technology of additive growth by the method of microplasma powder surfacing was used. To confirm the operability of restored parts, a set of studies of samples grown using the same repair technology was conducted. At the same time, it was established that the chemical composition of the deposited metal corresponds to the requirements of the technical conditions-» the microstructure of the deposited metal after heat treatment corresponds to the normal heat-treated state of the alloy ЭП648-ВИ (ХН50ВМТЮБ-ВИ), the level of mechanical properties of the grown alloy with subsequent serial heat treatment (aging at 700ºC, exposure -16 hours) is not lower than the forging level used in serial production of the part.

Applications of H2-Enriched syngas and slag products from plastic wastes via novel plasma dual-stage-arc pyrolysis

Sustainable plastic waste management in the prevailing ‘new-normal’ post-pandemic scenario calls for calorific waste plastic up-cycling into high-end product recovery pathways. The present work employed a novel dual-stage arc plasma pyrolysis reactor to recover syngas and slag products from mixed plastics and Low-Density Polyethylene and Polyethylene Terephthalate (LDPE-PET) plastic waste feeds. Syngas product yield decreased while the solid slag yield increased with rising arc current, attaining 75% and 25% for mixed plastic waste feed and 59% and 41% for LDPE-PET wastes, respectively, at 200A arc current. The resultant syngas composition showed 83% and 77% H2 while 1.7% and 2.7% CO for mixed plastic waste-feed and LDPE-PET wastes, respectively, with no significant presence of CO2. Slag characterization studies revealed the presence of scattered pores on the slag surface, graphitic nanostructures due to scraped carbon depositions from electrode tips and the absence of aromatic groups due to complete conversion. High carbon content was observed in the slag due to the dissociation of lighter hydrocarbon and carbon dioxide on dual-arc exposure in two stages, underscoring the higher efficiency. For holistic integrated circular onsite ‘plastic waste-to-resource’ recovery-cum-application, electricity was generated from the resultant syngas and the slag was used for the manufacture of tiles in the community platform. Techno-economic evaluation of an up-scaled plasma pyrolysis facility shows the power recovery of 3.5 kWh/kg of waste plastic, with a net annual profit of $2800 and a payback period of 1.7 years. The findings of the present work suggest that the proposed integrated dual-arc plasma pyrolysis based plastic waste-to-resource recovery in circular-economy model has a viable outcome.

Towards the Understanding of Parameters Allowing to Anticipate the Precipitation Reaction of Metallic Precursors in Humid Air Gliding Arc Plasma Reactor

Towards the Understanding of Parameters Allowing to Anticipate the Precipitation Reaction of Metallic Precursors in Humid Air Gliding Arc Plasma Reactor

Simulation of a Microwave Plasma Torch Used for Hydrogen Production via Methane Pyrolysis

ABSTRACTHydrogen is often envisioned as a green fuel and energy carrier. However, a greenhouse gas‐free production method is still needed for this purpose. A promising method is the pyrolysis of methane. In this study, we present the three‐dimensional simulation of methane pyrolysis in a microwave plasma torch operated in an argon–methane mixture. Due to the high gas temperatures, the chemistry is dominated by reactions between neutral particles. Therefore, the plasma is treated only as a heat source using space‐resolved gas temperature measurements as input. The end‐of‐pipe results of the simulation are compared to measured values, showing good agreement for methane conversion.

Optimizing plasma arc cutting processes using physics-based metaheuristic algorithms: a comparative analysis

Optimizing plasma arc cutting processes using physics-based metaheuristic algorithms: a comparative analysis

Modeling and experiments on plasma ignition of Ekibastuz coal in the form of dust

Due to the low cost of coal and the fact that it is readily available in most parts of the world, coal is a convenient fuel source. Despite the inefficiency of the systems when it comes to converting heat energy into electricity, new technologies are necessary in order to improve their efficiency. In contrast to traditional methods of starting-up boilers and stabilizing combustion, plasma ignition and combustion stabilization (PICS) of pulverized coal flames offers an effective and sustainable alternative to the use of fuel oil or gas. This technology involves heating the air-coal mixture with electric arc plasma until the coal devolatilizes and the coke residue partially gasifies. Consequently, low-rank coal is converted into a highly reactive two-component fuel (HRTF) consisting of combustible gas and coke residue. For these processes in a plasma-coal burner (PCB) using Ekibastuz coal in the form of dust, a kinetic analysis was conducted using the PlasmaKinTherm program. Modeling the kinetics of PICS of pulverized fuel allowed changes in temperature, velocity, and concentration to be determined along the length of a PCB. The composition, degree of carbon gasification, and temperature of a stable coal-dust flame were determined using plasma ignition of solid fuel. Based on the comparison between experimental and calculated data, it was found that the results were satisfactory.

Prediction of Welding Mode for the Effect of Plasma Gas Flow Rate on the Mechanical and Microstructural Characteristics of Plasma Arc Welded Titanium Alloy Joints

Prediction of Welding Mode for the Effect of Plasma Gas Flow Rate on the Mechanical and Microstructural Characteristics of Plasma Arc Welded Titanium Alloy Joints