直流非转移弧热等离子体喷枪加热效率分析

利用计算机模拟技术,采用有限容积方法,针对自制的低能耗、高效率内送粉等离子喷涂设备,对喷枪内部影响喷涂热效率的因素进行了分析。研究结果表明通过适当提高进气流量、提高混合气体中的氮气或氢气含量和减少喷枪通道长度,均能提高等离子喷枪热效率。而电流的大小以及喷枪的通道直径对热效率无显著影响。     

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     

小功率等离子体射流的流特性

采用焓探针对小功率(5kW)热喷涂等离子体射流的焓、温度和速度进行了测量和计算。研究了气体成分、流量、电弧电压和电流对等离子流体的焓、温度和速度分布的影响。结果表明,对于单一氩气等离子体,当使用新喷嘴时,增大氩气流量能够使喷嘴内部电弧弧根向出口方向移动,从而增加等离子体射流的焓、温度和速度。对于Ar-N2等离子体,增加气体中氮气的含量,会提高等离子电弧电压,在同样的输入功率下,改变等离子电流和电压对等离子体的焓、温度和速度影响较小。对于Ar-N2等离子体,增加氢气含量会明显地提高等离子射流的速度和热传递。     

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.     

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采用焓探针对大气压力下热喷涂等离子体射流的焓和温度进行了测量和计算,研究了氩气流量变化、电流变化和喷涂距离对等离子射流的焓和温度分布的影响。结果表明,氩气流量不变的情况下,随着功率的增加等离子体的焓值和温度增加;电流保持不变时,随着氩气流量的增加等离子体的焓值和温度不断减小,随着距离喷嘴出口轴向距离的增加,等离子体的焓值和温度都大幅度的降低;氩气流量变化对喷枪热效率影响不大,功率增大时,喷枪热效率增加显著,喷枪热效率最高可达到60%。     

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。     

一种新型大气压毛细管介质阻挡放电冷等离子体射流技术

介绍一种结构设计简单、操作运行方便的新型毫米量级大气压冷等离子体射流发生技术.这种射流可以在大气压条件下，利用多种工作气体(如Ar,He,N₂)，通过毛细管介质阻挡放电(DBD)的方式实现.使用频率为33kHz，峰值电压为1—12kV的双向脉冲电源，利用Ar,He,N₂等工作气体，在毛细管内形成了稳定的冷等离子体射流.放电区域的光辐射空间分布利用商用CCD摄像机记录，从中研究放电形态和空间分布，观察到了在DBD区域的流动气体放电和在毛细管出口处形成的等离子体射流 关键词： 冷等离子体射流 毛细管介质阻挡放电 射流射程 射流激发温度     

Characteristics of helium DC plasma jets at atmospheric pressure with multiple cathodes

A novel DC plasma torch with multiple cathodes is developed for generating laminar, transitional and turbulent plasma jets. The jet's characteristics, including jet appearance, voltage fluctuation, thermal efficiency, specific enthalpy, and distributions of temperature, pressure, and velocity, are experimentally investigated. The results show that as the gas flow rate increases, the plasma jet transforms first from the laminar state to the transitional state and second to the turbulent state. Compared with the transitional/turbulent jet, the laminar jet possesses not only a better stability and a longer hightemperature zone but also a higher average/core temperature and a higher specific enthalpy at the nozzle's outlet. With the change of jet states from the laminar to the turbulent flow, the core pressure and velocity at the nozzle's outlet increase,while the decaying rates of temperature/pressure/velocity along the jet's axial direction increase sharply. Furthermore, applications of laminar, transitional and turbulent jets for zirconia spray coating are described. The test results indicate that the long laminar jet is favorable for the deposition of a high-quality coating because the powder particles injected into the laminar jet may have better heating and lower kinetic energy.     

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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通过构建等离子体数字测控系统,测量了等离子体发生器不同工况下的工作参数,包括工作气体流量、冷却水温升、弧电压与弧电流等。运用能量平衡原理,计算了等离子体发生器出口射流平均焓值、平均温度及其分布。结果表明,在等离子体发生器的出口处,射流温度呈抛物线分布,增加主气气体流量,射流焓值与温度呈下降趋势,而添加氢气为辅助工作气体时,射流焓值与温度将会得到显著提高。     

Effect of powder loading on the excitation temperature of a plasma jet in DC thermal plasma spray torch

A DC non-transferred mode plasma spray torch was fabricated for plasma spheroidization. The effect of powder-carrier gas and powder loading on the temperature of the plasma jet generated by the torch has been studied. The experiment was done at different input power levels; the temperature of the jet was within 5000–7000 K argon was used as plasma gas and powder-carrier gas. Nickel powder particles in the size range from 40 to 100 μm were processed. The temperature of the jet was estimated after flowing powder-carrier gas only into the plasma jet and with powder-carrier gas feeding powder into the flame. On introduction of powder-carrier gas and powder loading the temperature of the jet was found to decrease appreciably down to 11%. The temperature of the plasma jet was estimated using the Atomic Boltzmann plot method.     

层流等离子体射流温度与速度测量

本文分别应用光谱诊断、水冷皮托管及小尺寸杆状热流探针,对自由射入空气中的纯氩层流等离子体射流中心最高温度、滞止压力以及最大热流密度进行了测量,由测量结果导出了层流射流的中心最大速度,得到了射流气体温度和速度的轴向分布及其随工作电流和气流量变化的一些规律,探讨了气体的温度和速度对其向探针表面换热系数的影响。     

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     

层流等离子体制备球形氧化铝粉末的实验研究

为研究非转移弧层流等离子体制备面向新材料领域的μm级球形氧化铝粉末的能力,使用自制的非转移弧分段式阳极层流等离子体球化设备,以载气送粉的方式,对η相的不规则μm级三氧化二铝粉末进行等离子体球化处理,并采用均匀设计法,研究等离子体发生器和送粉器不同的工作参数对氧化铝粉末球化率的影响规律。结果表明,实验所采用的直流非转移弧层流等离子体发生器能有效制备球化率接近100%的高球化率球形氧化铝粉末。实验发现,高球化率、高分散性和粒径大小均匀的球形氧化铝粉末可在不同工艺参数组合下制备,并证明了采用非转移弧分段式阳极层流等离子体发生器可实现较低功率下制备较高球化率球形氧化铝的可行性。实验还通过XRD与PDF卡片索引技术对球化前后的氧化铝粉末进行了物相定性分析,发现η相的氧化铝粉末经射流作用转化成了Corundum型的氧化铝粉末。     

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.     

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为了提高等离子体废物处理效率,根据磁流体动力学理论,利用计算流体力学软件FLUENT,采用磁矢量势的方法对直流双阳极非转移型电弧等离子体炬进行了二维轴对称数值模拟。计算中采用了SIMPLE算法。数值模拟得到了等离子体的温度、速度等分布。结果表明,等离子体的温度随着轴向距离的增加而减小,随弧电流增加而增加;其速度随着轴向距离的增加而先增大后减小,随弧电流增加而增加;等离子体炬出口处的温度和速度随着径向距离的增加而减小。这些结果与实验结果基本相符。     

超声速等离子体射流的数值模拟

基于可压缩的全Naiver-Stokes方程，利用PHOENICS程序对由会聚 辐射阳极形状等离子体炬产生的超声速等离子体射流进行了数值模拟.考虑了等离子体的黏性、可压缩性以及变物性对等离子体射流特性影响.研究了超声速等离子体射流的流场结构特性以及不同环境压力对等离子体射流产生激波结构的影响.结果表明，超声速等离子体射流在喷口附近形成的周期性激波结构是其和环境气体相互作用的结果. 关键词： 等离子体炬 超声速等离子体射流 PHOENICS     

Comparative measurements on thermal plasma jet characteristics inatmospheric and low pressure plasma sprayings

The ion and electron temperatures and plasma flow velocities are measured and compared between atmospheric and low pressure plasma spraying systems. The measurements of ion temperature for two systems are carried out by an optical emission spectroscopy which uses the relative emissivities of isolated Ar I emission lines. The electron density and temperature are measured by a Langmuir probe rotating across the plasma jets. The ion saturation currents collected by a Mach probe at two orientations, perpendicular and parallel to the plasma jet, determine the flow velocity. The spatial distributions of electron density, plasma flow velocity, and the associated shock activity in thermal plasma jets are discussed in conjunction with their direct dependency upon the ambient pressures as well as the torch powers. Measurements on temperatures and velocity profiles of thermal plasma jets reveal the general features of the LPPS jet characteristics, i.e., higher velocity flow with lower temperature, longer heating zone of expanded flame, and more extended accelerating zone compared with those of the APS jets. The shock activity clearly exists in the form of standing shock waves in the plasma jet of LPPS in view of flow compression and abrupt velocity drop which are appeared in the results of measurements on the variations of electron density and flow velocity along the plasma jet. In the center of the plasma jet of APS, the electron density is high enough to reach the LTE criterion, and the difference between ion and electron temperatures becomes insignificant as the torch input power increases     

Effect of current connection to the anode nozzle on plasma torchefficiency

Experiments have been performed to demonstrate the influence of the location of the electric power connection to the anode nozzle on the efficiency of DC plasma torches. The DC plasma torch used in these experiments offers the flexibility to work with different anode geometries and the possibility of connecting the electrical power to the anode at two different locations. For each set of experiments, the controllable parameters such as total gas flow rate, gas composition, and electric current were kept constant, changing only the location of the electrical connection to the anode nozzle. The efficiency of the torch, derived from a conventional energy balance, shows a significant change as the location of the electrical connection to the anode nozzle is changed. The measured mean voltage as well as the amplitude of the voltage fluctuations were also affected by the location of the electrical connection to the anode nozzle. An explanation for the arc behavior is given, based on an analysis of the forces acting on the anode arc column and their influeuce on the variation of the arc column length. Experimental data are in good agreement with analytical predictions     

Numerical analysis of nitrogen-mixed argon plasma characteristicsand injected particle behavior in an ICP torch for ultrafine powdersynthesis

A numerical model is presented for the analysis of plasma characteristics of an ICP torch and gas mixing effects on the plasma when a nitrogen gas is added into the argon plasma as a carrier or sheath gas at the torch inlet, The fluid equations describing the plasma flow and temperature fields and the diffusions between two different gases are solved along with a magnetic vector potential equation for electromagnetic fields. The trajectory and the temperature change with time for a particle injected into the plasma are also investigated by a plasma-particle interaction model to find out optimum injection conditions for the synthesis of ultrafine nitride ceramic powders, It is found from the calculations that the nitrogen-mixed argon plasma with a nitrogen sheath gas is more favorable than the plasma with a nitrogen carrier gas for the reaction kinetics of nitride synthesis. It is also found that the radial injection through the holes of the tube wall Is preferable to the axial injection at the torch inlet for the complete evaporation of injected particle and the effective chemical reaction of reactant vapor with nitrogen. For the radial injection in an ICP torch of 20 cm in axial length, the optimum injection locations and initial velocities of 50 μm aluminum particles are found for synthesizing aluminum nitride are in the range of 6~12 cm apart from the torch inlet and over 15 m/s, respectively