Three—dimensional modelling of the flow and heat transfer in a laminar non—transferred arc plasma torch

By experimental observation we show that the plasma flow and heat transfer within a direct current (DC) nontransferred arc plasma torch always show appreciable three-dimensional (3D) peculiarity even when the geometrical construction of the torch and working gas admission and external electrical collection conditions are completely axisymmetrical.Previous two-dimensional (2D) modelling studies cannot predict the 3D peculiarity of the plasma torch.We have successfully performed 3D modelling,and in this paper we present the modelling results for the plasma flow and heat transfer characteristics in a laminar DC non-transferred are argon plasma torch.The predicted arc-root location on the surface of the torch anode and arc voltage compare favourably with the corresponding experimental results.     

Study of operating conditions of plasma spray torch using lowelectric power levels

The scaling-down of plasma spray torches is connected with problems of anodic arc attachment fluctuations. It Is known that thermally constricted arcs in molecular gases generate unstable anodic arc roots in the nozzle of the torch. Moreover, using a usual plasma spray torch at reduced electrical power level in an argon-hydrogen gas mixture at a pressure of about 120 mbar, the arc is strongly influenced by hydrodynamic forces. Especially, its long time behavior shown by the arc voltage course is very variable and nonreproducible. It is the purpose of this work to optimize the nozzle geometry and the gas flow rate in order to obtain stabilized operating conditions of the plasma torch for an arc current of 100 A. It will be shown that the design of the entrance region and the diameter of the anodic nozzle influence the are column motion as well as the level and the frequency of the voltage fluctuations. With a particularly modified anodic nozzle, stable and reproducible operating conditions of the plasma torch, which is used to synthesize diamond layers, will be obtained     

Processes and properties of electric arc stabilized by water vortex

Experimental investigation of an electric arc stabilized by a water vortex was carried out in a DC arc plasma torch for the power range 90-200 kW. Volt-ampere characteristics of the arc as well as the power balance were determined separately for the part of the arc column stabilized by water and for the remaining part between the nozzle exit and the external anode. The temperature of arc plasma close to the nozzle exit was determined by emission spectroscopy. Negatively biased electric probes in the ion collecting regime were used for determination of the plasma flow velocity. The measured temperatures up to 27000 K, and velocities up to 7 km/s are higher than the values commonly reported for plasma torches with DC arcs stabilized by a gas flow. Mass and energy balances within the arc chamber were determined from the experimental results. The radial transport of the energy by radiation was identified as a decisive process controlling the arc and plasma properties. The balance of radial energy transport was studied. The ratio of energy spent for evaporation of the water to the energy absorbed in the evaporated mass is very low in the water stabilized arc. This is the principal cause of high plasma temperatures and velocities found by the measurements     

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     

Plasma generation for the plasma cutting process

This study is an attempt to estimate the overall properties, viz. the thermal power and force, of an intense plasma jet produced by a plasma cutting torch, and to relate the properties of the plasma to the diameter of the nozzle of the plasma torch and the flow rate of plasma-forming gas. For cutting metallic plates using a thermal plasma, a narrow plasma jet is produced by means of a transferred electric are between an electrode in a plasma torch and the material to be cut. The power density and pressure exerted by the plasma jet on the material at the region of cut needs to be high so that a straight cut, without dress at the bottom of the plate, can be obtained. A simple theory to describe the behavior of the arc in a plasma cutting torch has been developed to predict the are radius, pressure, and arc voltage at the nozzle exit as a function of are current for a range of nozzle sizes and air flow rates. The results obtained are in good agreement with the measured values for an air plasma cutting torch nominally rated for 100-A operation. The relationships between the mass flow rate of plasma gas, plasma power, and arc force have been discussed in the light of design of plasma torches for plasma cutting     

Fluctuation of arc plasma in arc plasma torch with multiple cathodes

Fluctuation phenomena commonly exist in arc plasmas, limiting the application of this technology.In this paper,we report an investigation of fluctuations of arc plasmas in an arc plasma torch with multiple cathodes.Time-resolved images of the plasma column and anode arc roots are captured.Variations of the arc voltage, plasma column diameter, and pressure are also revealed.The results indicate that two well-separated fluctuations exist in the arc plasma torch.One is the high-frequency fluctuation(of several thousand Hz), which arises from transferring of the anode arc root.The other is the low-frequency fluctuation(of several hundred Hz), which may come from the pressure variation in the arc plasma torch.Initial analysis reveals that as the gas flow rate changes, the low-frequency fluctuation shows a similar variation trend with the Helmholtz oscillation.This oscillation leads to the shrinking and expanding of the plasma column.As a result, the arc voltage shows a sinusoidal fluctuation.     

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采用了数值模拟与实验结合的方法研究了用于模拟放射性固体废物玻璃固化的非转移弧型等离子体炬的电、热特性。基于包括电弧室和开放空间在内的3D 模型得到了电弧等离子体和等离子体射流的温度场。根据计算结果,电弧室内的最高温度位于第一阳极内,达到41.77×10 K;弧电压的计算值高于实测值,二者之间的差异随着电流强度的增大而逐渐减小。采用该等离子体炬熔融模拟废物的实验发现,所确定的等离子体炬到炉底的距离能够满足废物熔融的要求,与计算的结果相符合。上述结果表明,数值模拟的结果可以作为等离子体炉工程设计的依据,并可以用作进一步分析等离子体炉炉膛内工艺过程的输入条件。     

Time-resolved imaging of anodic arc root behavior duringfluctuations of a DC plasma spraying torch

The fluctuating behavior of a Sulzer Metco F4 DC plasma gun has been investigated by simultaneous measurement of the time dependencies of the are voltage and of images from the nozzle interior. An end-on imaging arrangement using a mirror and a mask in the optical path from the are to the camera allows visualization of the anodic arc attachment by strongly attenuating the bright emission from the are column. With the torch operating in the restrike mode, sequences of images have been acquired in synchronization with several typical features of the are voltage fluctuations showing that the attachment nature changes during a restrike cycle. Multiple attachments which coexist at least during the 1 μs exposure time of the camera have been evidenced and are interpreted as a continuous process of creation/vanishing of successive arc roots with a smooth transfer of the current from one to the other. The anode wear is shown to have a strong effect on the root position over the anode periphery, with a preference for attachment in eroded regions. The effects of operation parameters such as current, gas flow and injector type on the attachment nature and position are also presented     

Experimental study for the optimization of plasma torch operations

In this paper the electric and efficiency attributes of a low-powered dc plasma torch has been investigated. Torch operations require reproducibility, reliability and economicity to be attained. The characterisation allowed to scope operative ranges on the basis of minimum voltage fluctuations and maximum thermal efficiency levels for different gas flow rates, anode dimensions, arc current and two process gases (Ar, N₂){\rm (Ar, N_2)}.     

大气压直流氩等离子体射流工作特性研究

介绍了一种新型大气压直流双阳极等离子喷枪,并对其电特性参数和发射光谱进行了测量.通过对氩等离子体射流的电信号进行时域和频域分析,研究了载气流量和弧电流的变化对射流脉动的影响,结果表明氩等离子体电弧的伏安特性呈上升趋势,射流脉动属于接管模式,电源特性中的交流分量引起的电压波动是影响氩等离子体射流脉动的主要因素. 通过光谱法测量了氩等离子体射流在弧室内和弧室出口的发射光谱,利用玻尔兹曼曲线斜率法计算了射流的激发温度,根据Ar I谱线的斯塔克展宽得到了射流的电子密度,并对等离子体射流满足局域热力学平衡(LTE) 关键词： 等离子喷枪 射流脉动 激发温度 局域热力学平衡     

放射性废物玻璃固化专用等离子体炬的数值模拟与实验研究

采用了数值模拟与实验结合的方法研究了用于模拟放射性固体废物玻璃固化的非转移弧型等离子体炬的电、热特性。基于包括电弧室和开放空间在内的3D 模型得到了电弧等离子体和等离子体射流的温度场。根据计算结果,电弧室内的最高温度位于第一阳极内,达到1.77×10⁴ K;弧电压的计算值高于实测值,二者之间的差异随着电流强度的增大而逐渐减小。采用该等离子体炬熔融模拟废物的实验发现,所确定的等离子体炬到炉底的距离能够满足废物熔融的要求,与计算的结果相符合。上述结果表明,数值模拟的结果可以作为等离子体炉工程设计的依据,并可以用作进一步分析等离子体炉炉膛内工艺过程的输入条件。     

直流纯氩层流等离子体射流的长度变化

采用主要由阴极、阳极以及介于阴极和阳极之间的中间段组成的直流非转移式电弧等离子体发生器,在大气压条件下,比较系统地研究了纯氩层流等离子体射流的长度随着弧电流、气体流量以及发生器结构而变化的规律。结果表明:层流射流的长度随弧电流和工作气流量的增加而增长;层流向湍流流动转变的临界气流量值随弧电流增大而提高;在发生器的伏安特性呈大梯度变化的情况下,射流长度随弧电流的变化幅度增大。     

Arc Root Attachment on the Anode Surface of Arc Plasma Torch Observed with a Novel Method

The arc-root attachment on the anode surface of a dc non-transferred arc plasma torch has been successfully observed using a novel approach. A specially designed copper mirror with a boron nitride film coated on its surface central-region is employed to avoid the effect of intensive light emitted from the arc column upon the observation of weakly luminous arc root. It is found that the arc-root attachment is diffusive on the anode surface of the argon plasma torch, while constricted arc roots often occur when hydrogen or nitrogen is added into argon as the plasma-forming gas.     

Anode Heat Transfer in a DC Electric ARC with Superimposed Axial Flow

A DC electric arc is operated in argon at pressures between 100 and 760 mm Hg, axial flow velocities from 0 to 100 m/sec, and currents from 50 to 200 amps to assess the influence of these parameters on anode heat transfer using a double-anode configuration consisting of two plane, parallel anodes. Since the anode arc attachment size is appreciably smaller than the anode surface area in these experiments, a method is developed using an optical and/or floating potential probes for measuring the size of the near-anode arc column. The relative variation of two perpendicular dimensions of the near-anode arc column for variation in the arc operating parameters (pressure, flow velocity, current, anode separation) are measured. The results reveal that the cross section of the nearanode column is not circular and the average local heat fluxes show a strong dependence on the gas pressure.     

保护气对切割弧特性影响的模拟研究

通过比较两种不同结构切割炬所产生的等离子体流场,发现保护气对等离子体的温度和速度分布影响很小.垂直保护气在切割炬喷口形成阻碍作用,造成切割炬内的压强有所升高,但是增加不大.两种结构保护气对切割弧的影响只是在炬喷口外的激波附近.加入保护气后激波的强度会减弱.相对于没有保护气的情况,保护气增加冷却作用,弧电压会略有升高.当改变保护气的成分时,发现弧柱区的氧气含量不受影响,所以保护气成分的改变不会影响到弧电压.计算发现轴线处氧气和周围气体的混合很少,在喷口下游10mm处,氧气的摩尔分数仍在90%以上. 关键词： 等离子体切割弧 保护气 数值模拟     

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介绍了自行研制的直流非转移弧等离子体炬的结构和工作原理。运用相似理论,研究了该等离子体炬的电热特性与运行参数,比如气体流量、弧功率的关系,并将计算值与实验结果进行了比较。结果表明,计算值与实验结果吻合较好,可以利用获得的公式来对炬进行结构改进和参数优化。     

外磁场对直流等离子体炬放电特性的影响

介绍了新研制的磁约束直流等离子矩设备,计算了螺旋管线圈的磁场分布,通过实验研究了磁场变化对等离子体矩放电特性和伏安特性的影响。     

Numerical modelling of a direct current non-transferred thermal plasma torch for optimal performance

A laminar steady-state 2D axisymmetric model of a direct current (DC) thermal plasma torch using a magneto-hydrodynamic approach has been developed. The model takes into account the entire torch system comprising the plasma gas injection, the inner region of the torch, and the jet exiting into the ambient environment. Numerical results are obtained for two different power inputs chosen from published experimental data. The temperature predictions at the torch exit are found in good agreement with experimental results. Velocity analysis of the plasma jet has been presented and the impact of electromagnetic force on jet velocity is analysed. The Lorentz force arising due to the coupling of fluid motion and electromagnetic forces shoots up the jet velocity to significantly high values near the cathode tip. Temperature and velocity profiles are in good agreement with the characteristics of a long laminar plasma jet. An operating value of heat transfer coefficient (h) has been suggested for optimal torch operation, thus ensuring a low anode erosion rate and acceptable thermal efficiency. The argon torch has the maximum temperature and longest jet length among the plasma gases considered.     

Production of long,laminar plasma jets at atmospheric pressure with multiple cathodes

Plasma jets from conventional non‐transferred arc plasma devices are usually operated in turbulent flows at atmospheric pressure. In this paper, a novel non‐transferred arc plasma device with multiple cathodes is introduced to produce long, laminar plasma jets at atmospheric pressure. A pure helium atmosphere is used to produce a laminar plasma jet with a maximum length of >60 cm. The influence of gas components, arc currents, anode nozzle diameter, and gas flow rate on the jet characteristics is experimentally studied. The results reveal that the length of the plasma jet increases with increasing helium content and arc current but decreases with increasing nozzle diameter. As the gas flow rate increases, the length of the plasma jet initially increases and then decreases. Accordingly, the plasma jet is transformed from a laminar state to a transitional state and finally to a turbulent state. Furthermore, the anode arc root behaviours corresponding to different plasma jet flows are studied. In conclusion, the multiple stationary arc roots that exist on the anode just inside the nozzle entrance are favourable for the generation of a laminar plasma jet in this device.     

Arc root dynamics in high power plasma torches — Evidence of chaotic behavior

Although plasma torches have been commercially available for about 50 years, areas such as plasma gun design, process efficiency, reproducibility, plasma stability, torch lives etc. have remained mostly unattended. Recent torch developments have been focusing on the basic understanding of the plasma column and its dynamics inside the plasma torch, the interaction of plasma jet and the powders, the interaction of the plasma jet with surroundings and the impingement of the jet on the substrate. Two of the major causes of erratic and poor performance of a variety of thermal plasma processes are currently identified as the fluctuations arising out of the arc root movement on the electrodes inside the plasma torch and the fluid dynamic instabilities arising out of entrainment of the air into the plasma jet. This paper reviews the current state of understanding of these fluctuations as well as the dynamics of arc root movement in plasma torches. The work done at the author’s laboratory on studying the fluctuations in arc voltage, arc current, acoustic emissions and optical emissions are also presented. These fluctuations are observed to be chaotic and interrelated. Real time monitoring and controlling the arc instabilities through chaos characterization parameters can greatly contribute to the understanding of electrode erosion as well as improvement of plasma torch lifetime.