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.     

Electromagnetic Properties of a New Microwave Plasma Torch with Double Resonance Configuration

In order to obtain a stable plasma and improve the performance of the torch for atomic emission spectroscopy(AES), the structure of microwave plasma torch(MPT) was analyzed. The transmission and distribution characteristics of the electromagnetic field of the torch configuration with two or three concentric tubes, as well as the metal spacer between inner and intermediate tubes with different depths were simulated with electromagnetic simulation software and verified by experiments. The results indicate that the inner tube of MPT plays an important role in strengthening the electric field intensity at the opening end of the MPT and redistributing the electromagnetic field in the whole torch by forming a double resonance configuration, and contributes to enhancing the macroscopic stability and the self-sustainment of the plasma. The stability of the plasma is proved to be excellent when the metal spacer between the inner and intermediate tubes is located at a place 20—30 mm away from the top opening of the torch. A proper location of the spacer can also avoid the formation of a static filament plasma or a rotating plasma rooted from the outer wall of the inner tube. With the help of morphological analysis, the underlying reason why MPT possesses a great tolerance to wet aerosols and air introduction was clearly made, that is, the formation region of the plasma formed with MPT is apparently separated from the reaction zone of it.     

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.     

Tomographic Measurements of Temperature Fluctuations in an Air Plasma Cutting Torch

A tomographic optical system and method based on evaluations of plasma radiation in a wavelength range of 559–601 nm were used to acquire temperature distributions in an air plasma cutting torch in planes perpendicular to the arc axis with a time resolution of 1 μs. The derived frequency spectra and distributions of temperature fluctuations represented by standard deviations have shown significant variations in distributions of instabilities, depending on the time scales which are taken into account. The results confirmed the decisive role of arc current ripple modulation in the arc temperature fluctuations.     

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.     

气相色谱-微波等离子体炬双检测器及其气相色谱的响应特性

提出并建立了气相色谱-微波等离子体炬(MPT)原子发射光谱和离子化双检测器系统. 以Ar气作为等离子体工作气体, O2气作为等离子体屏蔽气体, 同时获得了被测组分的原子发射和离子化信息, 并对不同种类有机化合物的相对响应系数及检出限进行了测定.     

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.     

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.     

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.     

流动分析技术在微波等离子体炬原子发射光谱分析中的应用

本文系统地介绍了微波等离子体煤（MPT）原子发射光谱分析技术从基础研究到商品化仪器的发展过程中流动分析技术所起的作用。论证了几项较简单技术的联用对于解决分析工作者所面临的一些复杂问题的可能性。     

Design and Characteristics of a Laminar Plasma Torch for Materials Processing

Thermal plasma jets have been widely used in various materials processing techniques. However, the conventional thermal plasma torches usually generate turbulent plasma jets with the disadvantages of high axial temperature gradient, a short jet length and difficulties in the process control relatively, limiting its applications to materials processing. Therefore, this paper proposes a new laminar plasma torch (LPT) working with pure nitrogen to generate laminar plasma jet (LPJ). Its design and structural characteristics, e.g. segmented anode, axial gas injection, parallel water cooling structure, etc., are detailed to ensure the stability, the favorable temperature and velocity distribution of the generated LPJ. Experiments on the characteristics of the LPT showed that the generated LPJ possessed high specific enthalpy (ranging between 10 and 90 kJ/g), long jet length (maximum length: 480 mm) and low axial temperature gradient, and its output power a current and the gas flow rate. In addition, the thermal efficiency of the LPT was experimentally determined to be ranging between 25 and 45 %. Furthermore, experiment and simulation on the application of the LPJ for surface quenching verified the even radial temperature distribution of the plasma jet and high heat flux density brought to the surface.     

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.     

Characterization of the Converging Jet Region in a Triple Torch Plasma Reactor

Enthalpy probe measurements were taken of the converging plasma plume in a triple torch plasma reactor and related to substrate heat flux measurements. Results show excellent entrainment of process gases injected into the converging plasma plume by way of the central injection probe. At lower pressures (40 kPa), the plasma volume is equivalent to at least a 3 cm diameter, 4 cm long cylinder, with relatively uniform temperature, velocity, and substrate heat flux profiles when compared to a typical dc arc jet. Converging plasma plume size, substrate heat flux, and enthalpy profiles are also shown to be a strong function of applied system power. Substrate heat flux measurements show smaller radial gradients than enthalpy probe measurements, because of the high radial velocity component of gases above the substrate boundary layer. Enthalpy probe measurements were also conducted for diamond deposition conditions and approximate temperature and velocity profiles obtained. Problems with the uniform gas mixture assumption prohibited more accurate measurements. Reproducibility of enthalpy measurement results was shown with an average standard deviation of 11.8% for the velocity and 7.6% for the temperature measurements.     

Synthesis of Ozone at Atmospheric Pressure by a Quenched Induction-Coupled Plasma Torch

The technical feasibility of using an induction-coupled plasma (ICP) torch to synthesize ozone at atmospheric pressure is explored. Ozone concentrations up to ~250 ppm were achieved using a thermal plasma reactor system based on an ICP torch operating at 2.5 MHz and ~11 kVA with an argon/oxygen mixture as the plasma-forming gas. The corresponding production rate and yield were ~20 g ozone/hr and ~2g ozone/kWh, respectively. A gaseous oxygen quench formed ozone by rapid mixing of molecular oxygen with atomic oxygen produced by the torch. The ozone concentration in the reaction chamber was measured by Fourier Transform infrared (FTIR) spectroscopy over a wide range of experimental conditions and configurations. The geometry of the quench gas flow, the quench flow velocity, and the quench flow rate played important roles in determining the ozone concentration. The ozone concentration was sensitive to the torch RF power, but was insensitive to the torch gas flow rates. These observations are interpreted within the framework of a simple model of ozone synthesis.     

Multiscale Finite Element Modeling of Arc Dynamics in a DC Plasma Torch

The dynamics of the electric arc inside a direct current non-transferred arc plasma torch are simulated using a three-dimensional, transient, equilibrium model. The fluid and electromagnetic equations are solved numerically in a fully coupled approach by a multiscale finite element method. Simulations of a torch operating with argon and argon–hydrogen under different operating conditions are presented. The model is able to predict the operation of the torch in steady and takeover modes without any further assumption on the reattachment process except for the use of an artificially high electrical conductivity near the electrodes, needed because of the equilibrium assumption. The results obtained indicate that the reattachment process in these operating modes may be driven by the movement of the arc rather than by a breakdown-like process. It is also found that, for a torch operating in these modes and using straight gas injection, the arc will tend to re-attach to the opposite side of its original attachment. This phenomenon seems to be produced by a net angular momentum on the arc due to the imbalance between magnetic and fluid drag forces.     

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.     

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.     

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.     

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.