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     

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     

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     

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.     

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     

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.     

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.     

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.     

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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。     

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。     

Numerical simulation on the influence of water spray in thermal plasma treatment of CF4 gas

Nitrogen thermal plasma generated by a non-transferred DC arc plasma torch was used to decompose tetrafluoromethane (CF₄). In the thermal decomposition process, water was used as a chemical reactant source. Two kinds of water spray methods were compared: water spray directly to the arc plasma flame and indirectly to the reactor tube wall. Although the same operating conditions of input power, waste gas, and sprayed water flow rate were employed for each water spray methods, a relatively higher decomposition rate was achieved in the case of water spray to the reactor wall. In order to investigate the effects of water spraying direction on the thermal decomposition process, a numerical simulation on the thermal plasma flow characteristics was carried out considering water injection in the reactor. The simulation was performed using commercial fluid dynamics software of the FLUENT, which is suitable for calculating a complex flow. From the results, it was revealed that water spray to the reactor wall and use of a relatively small quantity of water are more effective methods for decomposition of CF₄, because a sufficiently high temperature area and long reaction time can be maintained over large area.     

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。     

Axial variation of electron number density in thermal plasma spray jets

The electron number density has been measured in a plasma spray torch using Stark broadening of H and Ar-I (430 nm) line. A small amount of hydrogen (1% by volume in argon gas) was introduced to study the H line profile. Axial variation of electron number density has been determined up to a distance of 20 mm from the nozzle exit point of spray torch. The plasma torch was operated at 5 and 10 kW power level and flow of argon was kept at 25 liters per minute. Using the measured excitation temperature data under same experimental conditions, the electron number density has also been calculated using Saha equation. Comparison of electron number densities measured from Stark broadening with those derived from excitation temperature measurements under the assumption of local thermodynamic equilibrium (LTE) in thermal plasma jets indicate about the deviation from LTE in thermal plasma jets. The electron number density measurement using Stark broadening of Ar-I (430 nm) line will be particularly useful when only argon gas is used in thermal plasma jets.Received: 6 January 2003, Published online: 22 July 2003PACS: 52.70.Kz Optical (ultraviolet, visible, infrared) measurements - 52.77.-j Plasma applications - 52.25.-b Plasma properties     

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)}.     

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。     

Corrosion and oxidation properties of NiCr coatings sprayed in presence of gas shroud system

The oxidation of a NiCr bond coat during air plasma spraying was controlled by designing a gas shroud system attached to the plasma torch nozzle. Two nozzles, termed as “normal” and “high-speed” nozzles examined the effect of nozzle internal design on the microstructure and phase structure of coatings. X-ray diffraction and SEM morphologies showed that the shroud system reduced the oxidation of NiCr particles during the spray process. Compared with conventional air plasma spraying, the argon gas shroud reduced the coating hardness because the volume fraction of partially melted particles increased. The high-speed nozzle reduced the oxidation and hardness of NiCr coatings due to the increase of partially melted particles in the coatings.     

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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。     

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。     

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