Main Issues for a Fully Predictive Plasma Spray Torch Model and Numerical Considerations

Plasma spray is one of the most versatile and established techniques for the deposition of thick coatings that provide functional surfaces to protect or improve the performance of the substrate material. However, a greater understanding of plasma spray torch operation will result in improved control of process and coating properties and in the development of novel plasma spray processes and applications. The operation of plasma torches is controlled by coupled dynamic, thermal, chemical, electromagnetic, and acoustic phenomena that take place at different time and space scales. Computational modeling makes it possible to gain important insight into torch characteristics that are not practically accessible to experimental observations, such as the dynamics of the arc inside the plasma torch. This article describes the current main issues in carrying out plasma spray torch numerical simulations at a high level of fidelity. These issues encompass the use of non-chemical and non-thermodynamic equilibrium models, incorporation of electrodes with sheath models in the computational domain, and resolution of rapid transient events, including the so-called arc reattachment process. Practical considerations regarding model implementation are also discussed, particularly the need for the model to naturally reproduce the observed torch operation modes in terms of voltage and pressure fluctuations.     

A Thermodynamic Analysis of Nonequilibrium Argon Plasma Torches

The nonequilibrium process of argon plasma torches is analyzed theoretically. Thermodynamic diagrams of different degrees of ionization are developed to aid in understanding and analyzing the transition from chemical equilibrium to frozen flow in dc plasma torch operations. A thermodynamic model is developed to describe the nonequilibrium processes in a dc argon plasma torch. In the model the ionization process is approximated as a constant-pressure heating process, with little deviation from the equilibrium state upon completion of heating. If the plasma flow is frozen shortly after heating, the entropy increase is small during the transition from equilibrium to frozen flow. In this case the frozen flow will have nearly the same composition and entropy as the flow at the heating section exit. For singly ionized argon plasmas in the entropy range relevant to dc torch operation, the frozen flow solutions on the affinity–pressure diagram are found to be insensitive to entropy change. Therefore the present model predicts that argon plasmas generated at different power levels will have almost identical affinity at the torch exit for the same operating pressure. This prediction agrees with experimental observations except for very low torch power levels.     

Influence of the Shroud Gas Injection Configuration on the Characteristics of a DC Non-transferred Arc Plasma Torch

The characteristics of the plasma jet emanating from a dc non-transferred plasma torch is affected by many factors including arc current, type of gas, gas flow rate, gas injection configuration and torch geometry. The present work focuses on experimental investigation of the influence of shroud gas injection configuration on the I–V characteristics and electro-thermal efficiency of a dc non-transferred plasma torch operated in nitrogen at atmospheric pressure. The plasma gas is injected into the torch axially and shroud gas is injected through three different nozzles such as normal, sheath and twisted nozzles. The effects of flow rates of plasma/axial gas and arc current on I–V characteristics and electro-thermal efficiency of the torch holding different nozzles are investigated. The I–V characteristics and electro-thermal efficiency of the torch are found to be strongly influenced by the shroud gas injection configuration. The effect of arc current on arc voltage decreases with increasing the axial gas flow rate. At higher axial gas flow rate (>?45 lpm), the I–V characteristics of the plasma torch are similar irrespective of the nozzle used. The variation of electro-thermal efficiency with arc current is almost similar to that of arc voltage with arc current. As expected, the electro-thermal efficiency is increased when the axial gas flow rate is increased and at higher axial gas flow rate, it is not influenced by the arc current and shroud gas configuration. The plasma torch with normal nozzle may be better in the range of operating conditions used in this study.     

Effect of Anode Arc Root Position on the Behavior of the DC Non-transferred Plasma Jet at Field Free Region

A special bi-anode plasma torch that can change the anode arc root position without changing working gas flow rate has been developed to investigate the effect of anode arc root position on the behavior of the plasma jet. It has two nozzle-shaped anodes at different axial distances from the cathode tip. The arc root can be formed at anodes either close to the cathode tip (anode I) or far away from it (anode II) to obtain different attachment positions and arc voltages. The characteristics of pure argon plasma jets operated in different anode modes were measured in the field free region by using an emalpy probe, and the thermal efficiency of the torch was determined by measuring the temperature differences between cooling water flowing in and out of the torch. The results show that compared with the normal arc operated in anode I mode, the elongated arc operated in anode II mode significantly reduced the plasma energy loss inside the torch, resulting in a higher temperature and a higher velocity of the plasma jet in the field free region.     

Comparative Study of Flow Characteristics Inside Plasma Torch with Different Nozzle Configurations

A numerical analysis of the influence of different nozzle configurations on the plasma flow characteristics inside D.C plasma torches is presented to provide an advanced nozzle design basis for plasma spraying torches. The assumption of steady-state, axis-symmetric, local thermodynamic equilibrium, and optically thin plasma is adopted in a two-dimensional modeling of plasma flow inside the plasma torch. The PHOENICS software is used for solving the governing equations, i.e. the conservation equations of mass, momentum, and energy along with the equations describing the K-epsilon model of turbulence. The calculated arc voltages are consistent with the experimental results when arc current, gas inflow rate, and working gas are the same as the experimental parameters. Temperature, axial velocity contours inside plasma torches, profiles along the torch axis and profiles at the outlet section are presented to show the plasma flow characteristics. Comparisons are made among those torches. The results show that torches with different anode nozzle configurations produce different characteristics of plasma flows, which suggest some important ideas for the advanced nozzle design for plasma spraying. In order to validate the model and to show its level of predictivity, a comparison of the model with experimental results encountered in the literature is presented in the last part.     

Mathematical Simulation of Plasma-Chemical Coal Conversion

A mathematical model that describes the conversion of a coal-dust flow in a cylindrical plasma reactor is presented. The model describes a two-phase (coal particles + air) chemically reacting flow, which propagates in a channel with or without an internal heat source (an electric arc, a plasmatron torch, or exothermic chemical reactions). The model is based on the assumption that the process is quasi-stationary and one-dimensional; coal particles are taken isothermal, and ash is assumed an inert component. The model represents the composition of coals by their organic and mineral constituents. The model was implemented as a program for personal computers; calculations performed with the use of this program are in satisfactory agreement with experimental data.     

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.     

Effect of Cathode Nozzle Geometry and Process Parameters on the Energy Distribution for an Argon Transferred Arc

The influence of two nozzle geometries and three process parameters (arc current, arc length and plasma sheath gas flow rate) on the energy distribution for an argon transferred arc is investigated. Measurements are reported for a straight bore cylindrical and for a convergent nozzle, with arc currents of 100 A and 200 A and electrode gaps of 10 mm and 20 mm. These correspond to typical operating parameters generally used in plasma transferred arc cutting and welding operations. The experimental set up consisted of three principal components: the cathode-torch assembly, the external, water-cooled anode, and the reactor chamber. For each set of measurements the power delivered to each system component was measured through calorimetric means, as function of the arc’s operating conditions. The results obtained from this study show that the shape of the cathode torch nozzle has an important influence on arc behaviour and on the energy distribution between the different system components. A convergent nozzle results in higher arc voltages, and consequently, in higher powers being generated in the discharge for the same applied arc current, when compared to the case of a straight bore nozzle. This effect is attributed to the fluidynamic constriction of the arc root attachment, and the consequential increase in the arc voltage and thus, in the Joule heating. The experimental data so obtained is compared with the predictions of a numerical model for the electric arc, based on the solution of the Navier–Stokes and Maxwell equations, using the commercial code FLUENT©. The original code was enhanced with dedicated subroutines to account for the strong temperature dependence of the thermodynamic and transport properties under plasma conditions. The computational domain includes the heat conduction within the solid electrodes and the arc-electrode interactions, in order to be able to calculate the heat distribution in the overall system. The level of agreement achieved between the experimental data and the model predictions confirms the suitability of the proposed, “relatively simple” model as a tool to use for the design and optimization of transferred arc processes and related devices. This conclusion was further supported by spectroscopic measurements of the temperature profiles present in the arc column and image analysis of the intensity distribution within the arc, under the same operating conditions.     

Biomass conversion to hydrogen-rich synthesis fuels using water steam plasma

In this study, an experimental plasma-chemical reactor equipped with an arc discharge water steam plasma torch was used for biomass conversion to hydrogen-rich synthesis fuels. Glycerol and crushed wood were used as biomass sources. The effects of different conversion parameters including the water steam flow rate, treated material flow rate, and plasma torch power were studied. The experimentally obtained results were compared with the model based on the thermodynamic equilibrium. Additionally, the quantification of the plasma conversion system in terms of energy efficiency and specific energy requirement was performed. It has been found that the synthesis gas can be effectively produced from the biomass using water steam plasma.     

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.     

Penetration of plasma surface modification into porous media. III. Multiple samples exposed to CF4 and C2F4 low temperature cascade arc torch

The depth and possible mechanisms of the penetration of surface modification into porous media by a low temperature cascade are torch are investigated. Two different modes of such penetration (“flow controlled” and “diffusion controlled”) are evaluated. Three porous samples [stacks of 10 sheets of nonwoven fabrics of poly(ethylene terephthalate)each], placed at an axial distance of 24, 28, and 32 cm from the cascade are anode, are exposed to a low temperature cascade arc torch containing argon and CF₄ or C₂F₄, and surface properties of each of the sheets within treated porous samples are examined by ESCA. It is shown that interaction of chemically reactive species, created in the low temperature cascade arc torch, with the surface is not limited to the surface directly contacted by the torch. The flow controlled penetration is more pronounced for the outer layers, while diffusion controlled penetration is within the inner layers of the porous structure. Substantial differences in the fluorination effect of CF₄ (nonpolymer forming gas) and C₂F₄ (polymer forming gas) discharges for the second and third stacks are observed, that can be explained by the fact that the major effect of the CF₄ cascade arc torch treatment is based on the reaction of reactive species with the surface polymer molecules. The effect of C₂F₄ cascade arc torch treatment is based on the reactions of reactive species with polymers as well as reactions of reactive species themselves at the surface (plasma polymerization). Reactivity of the species created in C₂F₄ discharge is much higher compared to that created in CF₄ discharge, which is one of the major factors influencing penetration trends of low temperature cascade arc treatment into porous media. © 1995 John Wiley & Sons, Inc.     

Penetration of plasma surface modification. II. CF4 and C2F4 low-temperature cascade arc torch

The depth of surface modification by low-temperature cascade arc torch is investigated. A stack of 10 sheets of nonwoven fabrics of polyester fibers is exposed to a low-temperature cascade arc torch containing CF₄ or C₂F₄, and the fluorination effect is examined by ESCA. It is shown that interaction of chemically reactive species, created in a low-temperature cascade arc torch, with the surface is not limited to the surface contacted by the torch (flame). The results indicate that the fluorination effect is observed on surfaces which are shadowed from the torch by overlying fibers. The highest degree of fluorination is found on the second layer, rather than on the first layer which the torch contacts directly. No significant differences in the trends of penetration of CF₄ and C₂F₄ treatment through porous samples are observed. However, ESCA data show principal differences in chemical structures of the surfaces treated with CF₄ (nonpolymer-forming gas) and C₂F₄ (polymer-forming gas). These results indicate that chemically reactive species induced by the excited species of argon rather than primary species created by the ionization process seem to play predominant roles in the surface treatment as well as the low-temperature cascade arc torch polymerization of perfluorinated compounds. © 1994 John Wiley & Sons, Inc.     

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.     

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.     

Effects of Nozzle Length and Process Parameters on Highly Constricted Oxygen Plasma Cutting Arc

The influence of nozzle length and two process parameters (arc current, mass flow rate) on the plasma cutting arc is investigated. Modeling results show that nozzle length and these two process parameters have essential effects on plasma arc characteristics. Long nozzle torch can provide high velocity plasma jet with high heat flux. Both arc voltage and chamber pressure increase with the nozzle length. High arc current increases plasma velocity and temperature, enhances heat flux and augments chamber pressure and thus, the shock wave. Strong mass flow has pinch effect on plasma arc inside the torch, enhances the arc voltage and power, therefore increases plasma velocity, temperature and heat flux.     

Steam Plasma Methane Reforming for Hydrogen Production

Reactions of methane with water and CO₂ in thermal plasma generated in a special plasma torch with a water-stabilized arc were investigated. Steam plasma with very high enthalpy and low mass flow rate was produced in a dc arc discharge which was in direct contact with water vortex surrounding the arc column. Composition of produced gas, energy balance of the process and its efficiency were determined from measured data. The output H₂/CO ratio could be adjusted by a choice of feed rates of input reactants in the range 1.1–3.4. Depending on experimental conditions the conversion of methane was up to 99.5%, the selectivity of H₂ was up to 99.9%, and minimum energy needed for production of 1 mol of hydrogen was 158 kJ/mol. Effect of conditions on process characteristics was studied. Comparison of measured data with results of theoretical computations confirmed that the reforming process produces gas with composition which is close to the one obtained from the thermodynamic equilibrium calculations. Relations between process enthalpy, composition of produced syngas and process characteristics were determined both theoretically and experimentally.     

Influence of the Gas Injection Angle on the Jet Characteristics of a Non-transferred DC Plasma Torch

The non-transferred direct current (DC) plasma torch has been widely used in various industrial applications due to its special jet characteristics. The jet characteristics are determined by different factors, including the working parameters, the torch construction, the gas injection angle (GIA) etc. As there is little study on the influence of the GIA on the jet characteristics, experimental study on the GIA’s effects on the jet characteristics has been carried out on a specially designed non-transferred DC plasma torch, whose GIA can be changed by replacing a gas injection component. The arc voltages and thermal efficiencies of the plasma torch, the specific enthalpies and jet lengths of the plasma jets at different working conditions were obtained and analyzed. It has been found that the GIA greatly affects the arc voltage, the thermal efficiency, the specific enthalpy and the jet length. Based on these findings, plasma torch with appropriate GIA could be used to help generating the plasma jet with desired characteristics.     

A high-powered A.C. plasma torch for the arc heating of molten steel in the tundish

Current user's requirements for excellent product quality means that producers must discover the isothermal casting conditions which trill lead to top operating performance in the continuous casting process. In response to this requirement. a high-powered A. C. plasma arc heating system was adopted for the No. 4 Continuous Caster (No. 4CC) put into operation at Kakogawa Works. This heating system is a single-phase A.C. plasma type with two torches. This report describes research on the molten steel heating technique utilized by the A. C. plasma system, the effects of tundish atmosphere on the characteristics of plasma electric potter, and the counter- measures devised to increase the arc voltage using a suitable torch structure.     

Heat transfer in RF plasma sintering: Modeling and experiments

The mechanisms of heat transfer from an argon RF plasma, generated in a water-cooled quartz tube, to a sintering sample immersed into the plasma and to the walls of the plasma torch have been studied both analytically and experimentally for pressures from 1 to 50 torr. The model, based on the assumption of chemical equilibrium in a two-temperature plasma with rotational symmetry, includes the influence of the magnetic field and of the Knudsen number on the thermal conductivity of the plasma. At pressures below 20 torr heat transfer to the sintering sample is enhanced compared to heat transfer to the wall of the plasma torch. This nonsymmetry is attributed to the Hall parameter and Knudsen number effect. The relative importance of the two effects is a function of the pressure. A comparison with experiments, based on calorimetric and indirect heat transfer measurements for a range of pressures and power levels, indicates satisfactory agreement with analytical predictions, with the exception of larger discrepancies at higher power levels and relatively low pressures. For pressures below 5 torr, the chemical equilibrium assumption becomes questionable, i.e., the sintering model underestimates the heat transfer to the sintering sample.