A Computational Examination of the Sources of Statistical Variance in Particle Parameters During Thermal Plasma Spraying

Computational modeling is used to systematically examine many of the sources of statistical variance in particle parameters during thermal plasma spraying. Using the computer program LAVA, a steady-state plasma jet typical of a commercial torch at normal operating conditions, is first developed. Then, assuming a single particle composition(ZrO₂) and injection location, real world complexity (e.g., turbulent dispersion, particle size and density, injection velocity, and direction) is introduced ``one phenomenon at a time to distinguish and characterize its effect and enable comparisons of separate effects. Calculations are also performed wherein all phenomena are considered simultaneously to enable further comparisons. Both nonswirling and swirling plasma flow fields are considered. Investigating each phenomenon separately provides valuable insight into particle behavior. For the typical plasma jet and injection conditions considered, particle dispersion in the injection direction is mostsignificantly affected by (in order of decreasing importance): particle size distribution, injection velocity distribution, turbulence, and injection direction distribution or particle density distribution. Only the distribution of injection directions and turbulence affect dispersion normal to the injection direction and are of similar magnitude in this study. With regards to particle velocity and temperature, particle size is clearly the dominant effect.     

Heat Generation and Particle Injection in a Thermal Plasma Torch

The operation of plasma guns used for plasma spraying involves a continuous movement of the anode arc root. The resulting fluctuations of voltage and thermal energy input introduce an undesirable element in the spray process. This paper deals with the effects of these arc instabilities on the plasma jet, and the behavior of particles injected in the flow. The first part refers to the formation of the plasma jet. Measurements show that the static behavior of the arc depends strongly upon the plasma-forming gas mixture, especially the mass flow rate, of the heavy gas, injection mode, nozzle diameter, and arc current. These parameters control the electric field in the arc column, the arc length, its stability, and the gas velocity and temperature. The dynamic behavior of the arc is examined to determine how the tempeature and velocity of the plasma gas vary with voltage variations. Relationships between the gas velocity at the nozzle exit and the lifetime of the arc roots, and the independent operating parameters of the gun can be established from a dimensional analysis. The second part discusses the interaction between the plasma jet and the particles injected into the flow. The parameters controlling particle injection and trajectory are examined to determine how injection velocity must vary with particle size and density to achieve a given trajectory. The effect of the transverse injection of the powder carrier gas is investigated using a 3-D computational fluid dynamics code. Finally, the effect of the jet fluctuations on particle trajectory is studied under the assumption that the jet velocity follows the voltage variation. The result is a continuous variation of the particle spray jet position in the flow. Experimental observations confirm the model predictions.     

Particle dynamics and particle heat and mass transfer in thermal plasmas. Part I. The motion of a single particle without thermal effects

A particle injected into a thermal plasma will experience a number of effects which are not present in an ordinary gas. In this paper effects exerted on the motion of a particle will be reviewed and analyzed in the context of thermal plasma processing of materials. The primary purpose of this paper is an assessment of the relative importance of various effects on particle motion.Computer experiments are described, simulating motion of a spherical particle in a laminar, confined plasma jet or in a turbulent, free plasma jet. Particle sizes range from 5 to 50 µm, and as sample materials alumina and tungsten are considered.The results indicate that (i) the correction term required for the viscous drag coefficient due to strongly varying properties is the most important factor; (ii) non-continuum effects are important for particle sizes <10 µm at atmospheric pressure and these effects will be enhanced for smaller particles and/or reduced pressures; (iii) the Basset history term is negligible, unless relatively large and light particles are considered over long processing distances; (iv) thermophoresis is not crucial for the injection of particles into thermal plasmas; (v) turbulent dispersion becomes important for particle <10 µm in diameter.     

Particle dynamics and particle heat and mass transfer in thermal plasmas. Part III. Thermal plasma jet reactors and multiparticle injection

Thermal plasma processing involves complex interactions of particulates with plasmas. In previous studies (see Parts I and II of this series), an assessment of different effects has been made considering the dynamics and heat and mass transfer of a single particle immersed into a thermal plasma. The last paper of this sequence is concerned with the simulation of thermal plasma jet reactors and the effects caused by multiparticle injection.A mathematical model is proposed for the simulation of thermal plasma jet reactors, including the mixing phenomena between the jet and the surrounding gases by generalizing the governing equations for simple mixing flows. Also included is the density fluctuation effect by extending the K- model to a four-equation turbulence model combined with a probability density function. This model is internally consistent covering additional physical phenomena which are not covered by existing models. Unfortunately, its expected higher accuracy cannot be proven because of the present uncertainties associated with the input.For multiparticle injection, the simulation repeats calculations for single-particle injection, but with different initial conditions correcting the solutions by considering the coupling effects between particles and the plasma.The results indicate that (i) thermal plasmas show different mixing behavior in different gases; (ii) the density fluctuation effect is important since it causes large differences between the mass-weighted and unweighted time-averaged temperatures of thermal plasma jets; (iii) coupling effects become important when the particle loading rate exceeds half of the plasma mass flow rate; (iv) there are 16 constraints imposed on the modeling work which have to be considered for establishing a base for comparison with future experimental studies.     

Particle Injection in Direct Current Air Plasma Spray: Salient Observations and Optimization Strategies

External injection of high-melting point low thermal conductivity ceramics orthogonal to a typical direct current thermal plasma jet plays a vital role in determining the in-flight state of the particles and the process downstream. The interactions between low density ceramic particles and high temperature plasma jet is quite complex, which influences the spray process and associated deposition. Detailed in-flight particle diagnostics as well as spray stream visualization have significantly enhanced our capability to diagnose and control the process. In this paper we present some salient observations on the role of key variables on particle injection. A number of experiments were conducted using a 7MB torch (Sulzer Metco, Westbury, NY) with both Ar–H₂ and N₂–H₂ plasma gases, where the carrier gas flow to inject Yttria Stabilized Zirconia (YSZ) was varied systematically and the resulting in-flight particle state was captured using an array of particle and spray stream sensors arranged in a 3D set-up. A notable observation is the existence of a “sweet-spot” in the plasma jet where the particle temperatures and velocities achieved a maximum. This sweet-spot can be characterized by the plume position (location of centroid of the spray stream) rather than carrier gas flow rate and is independent of primary gas flows and other process/material conditions. This result suggests a possible approach to optimize particle injection independent of plasma-forming-torch-parameters. Controlling particle injection at this sweet-spot has shown to benefit the overall process efficiency (in terms of melting) and process reliability (both in-flight measurement and coating build-up) with concomitant application benefits.     

Laser Doppler anemometry under plasma conditions. Part I. Measurements in a d.c. plasma jet

A study is presented on the use of laser Doppler anemometry (LDA) techniques for the measurement of the gas and particle velocities under plasma conditions. Experimental data is presented for a d.c. plasma jet in which alumina particles are injected under different operating conditions. The results reveal that the plasma velocity at the exit of the jet is of the order of 200–300 m/s. The intensity of turbulence is as high as 30 to 40% in the free shear layer and the particle velocity distribution is shown to be asymmetric, with particle dispersion in the plane of injection considerably more important than that in the perpendicular direction. The average particle velocity depends on the composition of the plasma gas, the torch current, and power.     

Experimental study of effective particle heating by a thermal plasma flow confined in a porous ceramic tube

The heating of a single alumina particle (1 mm diameter) was experimentally investigated using a thermal argon plasma flow confined in a tube. Two kinds of tube were used; a porous ceramic tube (PCT) with a transpiration gas and a water-cooled copper tube (WCT). The temperature and velocity of the particle heated in a thermal plasma flow were measured at the exit of the tube by the calorimetric and optical method, respectively. The plasma temperature and velocity at the exit of the tube were also measured. The heating rate of a particle was estimated from these experimental results. According to the results, the heating rate of a particle is higher for PCT with a small flow rate of transpiration gas than for WCT. Therefore, PCT is effective for the particle heating.Notation A cross-sectional area - Bi Biot number - C constant - c _p specific heat - D diameter - h heat transfer coefficient - k thermal conductivity - L length of tube - l distance for heat conduction loss - M mass - m flow rate of plasma jet gas - Nu Nusselt number - P pressure - Pr Prandtl number - Q heat transfer rate - Q _p total heat delivered to the particle - r radial distance - T plasma temperature - T _p particle temperature - T temperature rise - t time - U plasma velocity - U _p particle velocity - x axial distance - density - viscosity - residence time of the particle - a atmospheric (static) - Ar argon - b bulk - c centerline - cond conduction - cu probe - f film - i entrance of the tube - free stream - loss heat transferred to the wall of the tube - p particle - r room - rad radiation - t total - W wall, sphere surface - wa water - 0 exit of the tube     

Influence of velocity and surface temperature of alumina particles on the properties of plasma sprayed coatings

In this paper are described the main characteristics of the plasma spraying process of alumina deposits, i.e., the temperature and flow field of the plasma jets obtained with the classical spraying torches, the injection of the particles into the plasma jet, the particle surface temperature and velocities in the plasma (measured for calibrated alumina particles), and the coating generation. The measurements on the alumina particles are compared with the predictions of a mathematical model. The experimental and computed particle velocities are in rather good agreement. However, this is not the case for the particle surface temperature. Possible reasons for the discrepancy are proposed (influence of the carrier gas, thermophoretic forces, and poor penetration of the particles into the plasma core even for an injection velocity twice that of the optimal calculated one, as shown by recent measurements). Finally the correlations between the particle velocities and surface temperature, and the properties of the alumina coating (porosity, crystal structure, mechanical properties) are studied.     

Improvement of plasma spraying efficiency and coating quality

A commercial torch has been modified to introduce an additional anti-vortex and shroud gas flow to counter the detrimental effects brought about by the vortex plasma gas flow which is used to stabilize the cathode arc attachment and to increase the anode life. Deposition efficiency and coating quality are used as criteria to judge the modified versus the nonmodified torch. High-speed videography and computerized image analysis systems are used to determine the particle trajectories, velocities, and the plasma jet geometry. The results show that the additional anti-vortex and shroud gas flow to the torch can keep the particles closer to the torch axis and reduce the amount of entrainment of cold air into the plasma jet. The consequence is that deposition efficiency and coating quality are substantially improved.     

Comparison between Two Turbulence Models and Analysis of the Effect of the Substrate Movement on the Flow Field of a Plasma Jet

In the first part of the present study, an appropriate inflow turbulent boundary condition is chosen. Then, a comparison is made between two turbulence models for a plasma jet discharged into air atmosphere. The plasma jet gas phase flow is predicted with the standard k–ɛ model and the RNG model of turbulence. Particles behavior is modeled using stochastic particles trajectories. A validation of the plasma jet model is made by comparison with experimental data. This part of the study shows that the flow features are better predicted with the RNG model. The choice of appropriate boundary conditions seems to be crucial for a better simulation of plasma thermal spraying. Afterwards, computations are performed for projection of Ni particles. It is found that the computed particles velocities and temperatures are also better predicted with the RNG model compared with the k–ɛ model. The second part of this study is concerned with the effect of the substrate movement on the gas flow field. This is performed in order to simulate a realistic coatings process where a relative movement between the torch and the substrate always exists. Three substrate velocities have been used and it is found that the flow fields are affected only very near the substrate wall.     

Plasma spraying of alumina: Plasma and particle flow fields

A comprehensive experimental examination of the interaction between a subsonic thermal plasma jet and injected alumine, particles is presented. Measurements of plasma velocity, temperature, and entrained air were obtained from an enthalpy probe and mass spectrometer combination. A diffusive separation, or demixing, of the Ar and He plasma gas was observed. Centerline plasma velocities and temperatures ranged from 1501500 m/s and 2000 to 14,000 K, respectively, in the region between the torch and a typical substrate location of 90 mm. Measurements of particle size, velocity, tempearture and local number density were obtained from a combination laser particle sizing system, Laser doppler velocimeter (LDV), and two-color pyrometer. Centerline temperatures and velocities for the nominally 30 m particles used were 2400–2800 K and 150–200 m/s, respectively.     

Particle behavior in thermal plasmas

In this overview, effects exerted on the motion and on heat and mass transfer of particulates injected into a thermal plasma are discussed, including an assessment of their relative importance in the context of thermal plasma processing of materials. Results of computer experiments are shown for particle sizes ranging from 5–50 μm, and for alumina and tungsten as sample materials. The results indicate that (i) the correction terms required for the viscous drag and the convective heat transfer due to strongly varying properties are the most important factors; (ii) noncontinuum effects are important for particle sizes <10 μm at atmospheric pressure, and these effects will be enhanced for smaller particles and/or reduced pressures; (iii) the Basset history term is negligible, unless relatively large and light particles are considered over long processing distances; (iv) thermophoresis is not crucial for the injection of particles into thermal plasmas; (v) turbulent dispersion becomes important for particle <10 μm in diameter; and (vi) vaporization describes a different particle heating history than that of the evaporation process which, however, is not a critical control mechanism for interphase mass transfer of particles injected into thermal plasmas.     

Study of Injection Angle and Carrier Gas Flow Rate Effects on Particles In-Flight Characteristics in Plasma Spray Process: Modeling and Experiments

This paper investigates the influence of particle injection angle on particle in-flight behaviors and characteristics at different primary and carrier gas flow rates through an integrated modeling and experimental approach. Particle in-flight status such as temperature, velocity, size and their distribution are analyzed to examine particle’s melting status before impact. Results from the experiments and numerical simulations both show that, when carrier gas flow rate is fixed, a small injection angle favors the particle melting and flattening. This behavior is independent of primary and secondary gas flow rates, spray distance and carrier gas flow rate. When both carrier gas flow and injection angle vary, a high carrier gas flow rate and a small injection angle are recommended for high particle temperature and velocity.     

Direct Measurement of the Gas Entrainment Into a Turbulent Thermal Plasma Jet

An experimental study is conducted to investigate the entrainment characteristics of a turbulent thermal plasma jet issuing from a DC arc plasma torch operating at atmospheric pressure. The mass flow rate of the ambient gas entrained into the turbulent plasma jet is directly measured by use of the so-called “porous-wall chamber” technique. It is shown that a large amount of ambient gas is entrained into the turbulent plasma jet. With the increase of the gas mass flow rate at the plasma jet inlet or the plasma torch exit, the mass flow rate of entrained ambient gas almost linearly increases but its ratio to the jet-inlet mass flow rate decreases. The mass flow rate of the entrained gas increases with the increase of the arc current or jet length. It is also found that using different ways to inject the plasma-forming gas into the plasma torch affects the entrainment rate of the turbulent plasma jet. The entrainment rate expression established previously by Ricou and Spalding (J. Fluid Mech. 11: 21, 1961) for the turbulent isothermal jets has been used to correlate the experimental data of the entrainment rates of the turbulent thermal plasma jet, and the entrainment coefficient in the entrainment rate expression is found to be in range from 0.40 to 0.47 for the turbulent thermal plasma jet under study.     

Diffusion phenomena of a cold gas in a thermal plasma stream

The present study involves both experimental investigation and mathematical modeling of the diffusion process of a cold gas injected into a main plasma stream. The cold gas (nitrogen or helium) was injected axially through a water cooled tube located along the centerline of an induction plasma torch. The 2-D distribution of the temperature, velocity and concentration profiles in the plasma flow were measured using enthalpy probe techniques. The results are compared with the predictions of a 2-D, LTE, turbulent mathematical model. The effects of the nature (composition) of the injected gas and its mass flow rate are investigated. The enthalpy probe measurements and the predictions of the model are in good agreement. The effective (turbulent and molecular) transport properties are estimated from a comparison of the measured and calculated profiles of the temperature, velocity and concentration fields. This study sheds light on the basic diffusion mechanisms involved in a widely used configuration of induction plasma reactors, i.e. in which the material to be treated is injected axially into the plasma, through a central water cooled tube.     

Solid-Phase Synthesis of Calcium Carbide in a Plasma Reactor

A laboratory-scale spout-fluid bed reactor with a dc plasma torch was used to study the solid-phase synthesis of calcium carbide. Calcium oxide powder with a mean particle size of 170 m was reacted with graphite powder (130 m). Argon was used to initiate the plasma and hydrogen gas was then added to increase power and raise the plasma jet enthalpy. Experimental results showed that the reaction took place in the vicinity of the plasma jet and that conversion to calcium carbide increased linearly with reaction time. The rate of conversion increased exponentially with plasma jet temperature, indicating that chemical reaction was the controlling mechanism. Microscopic analysis of the solid product showed that calcium carbide was formed around both reactants, and that the reaction followed a shrinking core model. Although melting and agglomeration of partially reacted particles occurred at high temperature, resulting in instability of the bed and impeding the reaction progress, high conversions are expected in a continuous process with optimized reactor design.     

Peak broadening from an electrothermal vaporization sample introduction source into an inductively coupled plasma

Signal broadening using electrothermal vaporization with inductively coupled mass spectrometry (ETV-ICPMS) occurs at a rate much faster than would be predicted by simple longitudinal diffusion. A Monte Carlo simulation that focused on particle motion within the transport tubing was created to elucidate the causes of this dispersion within ETV-ICPMS. Several parameters, including the diffusion coefficient, tube diameter, transport tube length, and flow rate were varied to discern their role in signal broadening. Using typical instrumental parameters, the parabolic flow profile generated by laminar flow of the carrier gas was shown to be the primary cause of dispersion. Manipulating the aforementioned variables to lessen the effects of laminar flow led to a decrease in dispersion. Conversely, increasing the role of laminar flow promoted broadening. The broadening processes should be applicable to any transient introduction system where material must be transported to a detection system. Due to the difference in the rate of broadening expected for particles of different sizes, the simulation was used to calculate the average size of particles generated in the ETV using different mass amounts of sample. No change in particle size (∼1 nm) was seen for mass amounts ranging from 10–10 000 pg, which suggests that the particle number is increased with increasing sample mass rather than the average particle size. Using this method of determining particle size, it might be possible to further evaluate the mechanisms of physical ‘carrier’ action.     

Two-temperature modeling of an arc plasma reactor

In this paper a two-temperature plasma model is established and applied to the injection of cold gases into an atmospheric-pressure, high-intensity argon arc. The required nonequilibrium plasma composition and the non-equilibrium transport properties are also calculated. The results show that the arc becomes constricted at the location of gas injection due to thermal and fluid dynamic effects of the injected cold flow. Enhanced Joule heating in the constricted arc path raises the electron as well as the heavy-particle temperatures. This temperature increase resists, via secondary effects, the penetration of the cold gas into the hot arc core which behaves more or less as a solid body as far as the injected flow is concerned. The temperature discrepancy between electrons and heavy particles is most severe at the location of cold flow injection, a finding which may have important consequences on chemical reactions in an arc plasma reactor.     

A Portable Plasma Sterilizer

An atmospheric microplasma jet system powered by an commercial transformer is developed for investigating the sterilizing efficiency of Escherichia coli in different conditions. The device can be hand-held and operated in the open air. The effect of carrier gas, gas flow rate, distance and treatment time of inactivation is studied. According to the experiment, plasma jet is able to inactivate all the bacteria on the surface in 20 s when the air flow rate is 5 L/min and the distance is 2.0 cm. Besides, the sterilization efficacy with different carrier gas follows an order as bellow: N₂ > air > O₂ > Ar. The measurements of malondialdehyde content, protein leakage quantity and Mg content are performed as well. In addition, the SEM after plasma treatment reveals that the integrity of E. coli cells is damaged and intracellular particles are excreted into the extracellular space. With discussions upon the mechanisms of surface sterilization, it is found that during the treatment of microplasma, it is mainly the etching actions of electrons and ions on the bacilli that kill the E. coli. Chemical effects rather than physical ones that are responsible for inactivation. Furthermore, the experiment results suggest that there may be better sterilization effect with gas mixture as carrier gas.