Relating Spectroscopic Measurements in a Plasma Cutting Torch to Cutting Performance

The relationship between plasma properties and cutting performance for a plasma arc cutting system was investigated. Plasma properties such as temperature and composition were measured using spectroscopic techniques in a 200 amp oxygen plasma cutting system. In addition to the plasma properties, the symmetry of the cylindrical cutting arc was also quantified. Cutting performance was measured by analyzing the edge quality of sample cuts. The most important measure of edge quality for this study was the angle of the cut edge. Operating parameters investigated included the effect of shield gas flow and geometry changes caused by cathode erosion. The measured plasma properties are used to account for the observed increase in recommended cutting speed for different consumable designs which operated at the same current level. A strong correlation was also shown between the measured arc symmetry and the cutting performance.     

Electric Arc Fluctuations in DC Plasma Spray Torch

Direct current plasma torches for plasma spraying applications generate electric arc instabilities. The resulting fluctuations of input electrical power hamper a proper control of heat and momentum transfers to materials for coating deposition. This paper gives an overview of major issues about arc instabilities in conventional DC plasma torches. Evidences of arc fluctuations and their consequences on plasma properties and on material treatments are illustrated. Driving forces applied to the arc creating its motion are described and emphasis is put on the restrike mode that depends on the arc reattachment and the boundary layer properties around the arc column. Besides the arc root shown as a key region of instability, the Helmholtz oscillation is also described and accounts for the whole plasma torch domain that can generate pressure fluctuations coupled with voltage ones.     

Computational Analysis of a Double Nozzle Structure Plasma Cutting Torch

Double arcing phenomenon is a limit to increasing the capacity of the plasma cutting torch. In an attempt to enhance the ability of being invulnerable to the double arcing, a double nozzle structure is introduced in this paper. The reason why the double nozzle structure is less vulnerable to the double arcing phenomenon than single nozzle structure is explored. Double nozzle structure allows the longer nozzle which may cause stronger shock wave. In order to evaluate the influence of shock wave on the cutting ability, the influence of nozzle length on the double nozzle structure plasma arc is investigated. The modeling results show that the longer nozzle produces the stronger shock wave outside the nozzle outlet, but the energy flux and momentum flux become concentrated after the shock wave and increases with the increasing of nozzle length. So the double nozzle structure improves the cutting ability of the plasma torch and meanwhile be less vulnerable to the double arcing phenomenon.     

Measurements of Temperature and Electron Number Density in a dc Argon–Nitrogen Plasma Torch—Supersonic Operation

The diagnostics study on supersonic argon/nitrogen plasma jets expanded into a low-pressure test chamber is carried out by means of emission spectroscopy and enthalpy probe measurement techniques. The spatial distributions of electron density, temperatures, and associated shock structure effects in plasma jets are investigated in conjunction with their direct dependency upon the chamber pressure. The experimental results show the occurrence and the position of different zones; i.e., supersonic expansion, stationary shock waves and subsonic jet at pressures below 51 kPa. Flow fluctuations due to the oblique shock wave at 39 kPa background pressure are observed and discussed. The electron density profiles show variations along the plasma axis that coincide with the position of the shock waves. The experimental results show the transition from the moderately under-expanded to the strongly under-expanded jet structure induced by lowering of the chamber pressure.     

Energy Fluctuations in a Direct Current Plasma Torch with Inter-Electrode Inserts Operated at Reduced Pressure

Direct current (dc) plasma torch with inter-electrode inserts has the merits of fixed arc length, relative high enthalpy and may show advantages in future plasma processes where stability and controllability are must-have. Energy fluctuations in the plasma may result from power supply ripple, arc length variation, and/or acoustic oscillation. Using an improved power supply with a flat waveform, the characteristics of an argon plasma energy instabilities under reduced pressure were studied by means of simultaneously monitoring the arc voltage and arc current spectrum. Dependence of the arc fluctuation behavior on the plasma generating parameters, such as the current intensity, the plasma gas flow rates and the vacuum chamber pressure were investigated and discussed. Results show that the plasma torch has a typical U-shaped voltage-ampere characteristic (VAC). The correlation between the VAC and the probability of energy distributions was studied. Through pressure measurements at the cathode cavity and the vacuum chamber, the existence of sonic flow in the inter-electrode insert channel was confirmed.     

Velocity Measurements for Arc Jets Produced by a DC Plasma Spray Torch

An optical method was used to determine the axial velocity of plasma jets produced by a DC plasma spray torch. Different experimental conditions were tested in order to systematically study the influence of the working parameters on the plasma velocity. In this way, the arc current ranged between 200 and 600 A, the gas flow rate between 30 and 80 slm, and the internal nozzle diameter between 6 and 10 mm; the plasma gases were either an Ar–H ₂ mixture or N ₂ . Rather well defined tendencies were observed and at the same time it appeared that the arc stability greatly influenced the fluctuations of the velocity.     

Torch Design Modification Using Micro-jets to Suppress Fluid Dynamic Instabilities in Plasma Arc Cutting

Highly constricted plasma arcs are widely used for metal cutting. One important characteristic of the cutting process is the consistency of the cut edge around the perimeter of the workpiece. Cut edge properties, including surface roughness, edge shape and dross formation, are presumed to depend on the local temperature and chemical composition of the cutting arc adjacent to the cut edge. Fluid dynamic instabilities in the arc boundary leading to entrainment of the low temperature ambient gas can have a strong effect on cutting performance. This paper describes the use of micro-jets to suppress fluid dynamic instabilities in the boundary layer of a plasma cutting arc. Previously developed optical diagnostics and analysis methods are used to characterize the arc boundary layer. Multiple nozzle designs have been investigated to quantify the effects of utilizing micro-jet flow around the arc column, and some relationships between nozzle design and cut quality are presented.     

Temperature Distribution in a Pilot Plasma Tundish: Comparison Between Plasma Torch and Graphite Electrode Systems

Arc, bath, and refractory wall temperatures are measured in a pilot transferred-arc plasma furnace by atomic emission spectroscopy (AES) and multiwavelength pyrometry. Argon plasma torch and graphite electrode with nitrogen as plasma gas are both examined and compared using the steel bath as anode. With argon, a two-slope characteristic curve is measured for arc temperature, which ranges from 9000 to 25,000 K. Another trend is observed with nitrogen for temperatures in the range 8000–12,000 K. In this latter case, the bath temperature is very sensitive to arc length: more than 100 K increase results in arc length rise from 50 to 150 mm. Experimental data shows the variation of heat transfer efficiency between the two configurations, which is supported by results about surface emissivity in the spectral domain 1–15 m.     

Measurement of Temperature in the Steam Arcjet During Plasma Arc Cutting

Spectroscopic measurements were performed by observing the plasma inside the kerf during cutting of stainless steel using direct current electric arc. Experiments were carried out on the plasma torch operated with the plasma gas composed of the vaporized mixture of water and ethanol; arc current was 60 A and cutting speed 30 cm/min. Emission spectral lines of neutral iron were used to experimental evaluation of the temperature of plasma in the kerf and close under the cut plate. Complicated nature of the plasma inside the kerf, including presence of metallic vapours and departures from equilibrium, was taken into account. Hence relatively reliable results were obtained, from which it was possible to get insight into the energy balance and cutting performance of the torch. Temperature of the plasma in the kerf was substantially lower than at the nozzle exit of the torch; however the temperature drop along the kerf was small.     

Spectroscopic Characterization of a Steam Arc Cutting Torch

Optical emission spectroscopy has been used to investigate the characteristics of a plasma jet produced by a steam arc cutting torch operated in air at atmospheric pressure. A procedure has been developed for simultaneous determination of temperature and pressure in the plasma jet as well as an effective nonequilibrium factor. It is based on comparison of a few experimental and simulated spectral quantities. The experimental data were obtained from the spectrum of H_β and OII lines centred at 480 nm. The existence of the shock wave structure characteristic of an underexpanded jet can clearly be deduced from the measured properties. In the first expansion region, the centreline pressure drops from about 1.4 atm at the nozzle exit to about 0.7 atm a few tenths of millimeter downstream. On the contrary, the centreline temperature remains almost unchanged within this region and reaches the value of about 23,000 K.     

Development of Atmospheric Pressure Low Temperature Surface Discharge Plasma Torch and Application to Polypropylene Surface Treatment

We have finally succeeded in producing the plasma jet by use of the surface discharge plasma torch that can be expected to make larger the diameter of torch in the comparatively easy way. It can be checked that the active species in the jet obtained are different depending on the direction of connection, and also it was clearly found that much O and N₂ is included in them. Consequently, etching was confirmed at the position of 10 mm from the torch end in the surface treatment of polypropylene film, but etching was not confirmed at the position of 20 mm.     

Studies on Excitation and Rotational Temperatures of an Oxygenshielded Argon Microwave Plasma Torch Source

IntroductionPlasma sources have been widely used for traceelemental analysis in atomic emission spectrometry(AES)or mass spectrometry(MS).The microwaveplasma torch(MPT),as a relative new source,wasfirst developed by Jinet al.in1985[1,2]and modifiedby Jin …     

Characteristics of Analyte Ionization in Low Power Microwave Plasma Torch

The ionization characteristics of the analytes in a low power Ar microwave plasma torch (MPT) was studied. The influence of forward microwave power, the flow rate of carrier gas and matrix element on the degree of ionization were observed. The axial profiles of the degree of the ionization of some elements were determined. The experimental results are very important for developing the new analytical source——microwave plasma torch (MPT).     

Effect of the Coil Angle in an Inductively Coupled Plasma Torch: A Novel Two-Dimensional Model

A two-dimensional model has been developed for the calculation of the electromagnetic (EM) fields generated by spiral coil currents, in order to obtain a better representation of the actual configuration used in a typical inductively coupled plasma (ICP) torch. In order to obtain the EM fields in a two-dimensional model, the change of EM field in tangential direction is neglected and the coil is assumed to be a concentric cylinder. In order to justify our assumption, the EM, flow and temperature fields resulting from five-ring coil and concentric cylinder coil are compared and the results are almost the same except for the EM field in the vicinity of the coil. In the case of the spiral coil, the coil current is inclined with respect to the horizontal plane. Therefore current in the cylinder coil is assumed to have the same inclined angle, which is split into tangential and axial components. The axial electric field and hence an axial current in plasma is induced by the axial component of the spiral coil current. Charge density is accumulated in the plasma, since the axial current cannot form a loop. In order to obtain the EM field and the charge distribution in the plasma generated by the spiral coil, the equations of axial vector potential and electrostatic potential have been derived. Due to the swirling Lorentz force (J_z×B_r) an axisymmetrical swirling fluid model is used to simulate the plasma flow in an axisymetrical configuration. With an inclined angle of the coil current being 3.7° and the frequency being 3 MHz, computational results show that the swirling Lorentz force causes plasma swirling with a maximum speed of 3.41 m/s near the plasma center when the injected sheath gas and central gas are not swirling. In these conditions, the real and imaginary parts of the maximum electrostatic potential are 0.95 V and 1.66 V, respectively. When the electrostatic field is neglected, the swirling velocity of the plasma is 3.95 m/s.     

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.     

Modeling of a DC Plasma Torch in Laminar and Turbulent Flow

A mathematical 2D representation is developed describing the temperature and the velocity profiles in a DC plasma torch and in the resulting plume. It is based on the resolution of conservation equations using the Simple method after Patankar. In the first part, we illustrate the effects of the turbulence, using, on the one hand, two Prandtl's mixing length models and, on the other hand, a standard k – model. We also show the influence of physical parameters like the inlet mass flow rate, the current intensity, and the kind of gas (argon or air) on the characteristics of the plasma. The second part of this study presents a comparison of the model with experimental results encountered in the literature. The profiles obtained at the exit of the torch are compared to the mathematical formulation used as boundary condition by the models taking into account only the plasma jet.     

Evaluation of Microwave Plasma Torch (MPT) as an Excitation Source for Determination of Mercury

The microwave plasma atomic spectrometry is an important branch of the plasma atomic spectrometry. Since the first use of microwave induced plasma(MIP) as an excitation source for spectral Chemical analysis by Broida and Chapmanin in 1958, especially the introduction of TM_(010) cavity by Beenakker in 1976 and of surfatron by Moisan in 1979 with which an atmospheric pressure helium MIP could be obtained, MIP has received considerable attention as a new excitation source for spectrometric analysis. However, since MIP suffers from the in ability to analyse the aqueous sam-     

微波等离子体炬光源基本特性的研究

用计算机化断层扫描成象技术研究了微波等离子体炬(MPT)放电的发射轮廓,证明该光源具有良好的对称性,并有一个有利于样品引入的中央通道,最佳分析区在炬管上方5～10 mm,用激光Thomson散射和Rayleigh散射技术测定了ArMPT和HeMPT放电的电子温度、电子密度和气体温度,证明MPT放电的电子温度很高而气体温度较低,是一种非热光源。其中的高能电子处于过布居状态,具有很高的激发能力。     

Use of Alternating-Current Plasma Torch for Processing Potentially Hazardous Substances

The decomposition of tetrachloromethane and tetrafluoromethane by air plasma in the presence of methane has been studied using an ac plasma torch of up to 500 kW power with rail electrodes. Methane reacts with air in the partial oxidation mode to form hydrogen, which reacts with a halogen to produce the hydrogen halide.     

Two-Temperature Chemical Non-equilibrium Modeling of Argon DC Arc Plasma Torch

Plasma Chemistry and Plasma Processing - A 2D two-temperature chemical non-equilibrium model has been developed to investigate the plasma characteristics inside a DC arc plasma torch of argon. In...