Modeling Study on the Entrainment of Ambient Air into Subsonic Laminar and Turbulent Argon Plasma Jets

Modeling study is performed to reveal the special features of the entrainment of ambient air into subsonic laminar and turbulent argon plasma jets. Two different types of jet flows are considered, i.e., the argon plasma jet is impinging normally upon a flat substrate located in atmospheric air surroundings or is freely issuing into the ambient air. It is found that the existence of the substrate not only changes the plasma temperature, velocity and species concentration distributions in the near-substrate region, but also significantly enhances the mass flow rate of the ambient air entrained into the jet due to the additional contribution to the gas entrainment of the wall jet formed along the substrate surface. The fraction of the additional entrainment of the wall jet in the total entrained-air flow rate is especially high for the laminar impinging plasma jet and for the case with shorter substrate standoff distances. Similarly to the case of cold-gas free jets, the maximum mass flow-rate of ambient gas entrained into the turbulent impinging or free plasma jet is approximately directly proportional to the mass flow rate at the jet inlet. The maximum mass flow-rate of ambient gas entrained into the laminar impinging plasma jet slightly increases with increasing jet-inlet velocity but decreases with increasing jet-inlet temperature.     

Comparison of Laminar and Turbulent Thermal Plasma Jet Characteristics—A Modeling Study

Modeling results are presented to compare the characteristics of laminar and turbulent argon thermal plasma jets issuing into ambient air. The combined-diffusion-coefficient method and the turbulence-enhanced combined-diffusion-coefficient method are employed to treat the diffusion of ambient air into the laminar and turbulent argon plasma jects, respectively. It is shown that since only the molecular diffusion mechanism is involved in the laminar plasma jet, the mass flow rate of ambient air entrained into the laminar plasma jet is comparatively small and less dependent on the jet inlet velocity. On the other hand, since turbulent transport mechanism is dominant in the turbulent plasma jet, the entrainment rate of ambient air into the turbulent plasma jet is about one order of magnitude larger and almost directly proportional to the jet inlet velocity. As a result, the characteristics of laminar plasma jets are quite different from those of turbulent plasma jets. The length of the high-temperature region of the laminar plasma jet is much longer and increases notably with increasing jet inlet velocity or inlet temperature, while the length of the high-temperature region of the turbulent plasma jet is short and less influenced by the jet inlet velocity or inlet temperature. The predicted results are reasonably consistent with available experimental observation by using a DC arc plasma torch at arc currents 80–250 A and argon flow rates (1.8–7.0)×10⁻⁴ kg/s.     

Modeling on the Momentum and Heat/Mass Transfer Characteristics of an Argon Plasma Jet Issuing into Air Surroundings and Interacting with a Counter-Injected Argon Jet

Modeling study is performed to reveal the momentum and heat/mass transfer characteristics of a turbulent or laminar plasma reactor consisting of an argon plasma jet issuing into ambient air and interacting with a co-axially counter-injected argon jet. The combined-diffusion-coefficient method and the turbulence-enhanced combined-diffusion-coefficient method are employed to treat the diffusion of argon in the argon–air mixture for the laminar and the turbulent regimes, respectively. Modeling results presented include the streamline, isotherm and argon mass fraction distributions for the cases with different jet-inlet parameters and different distances between the counter-injected jet exit and the plasma torch exit. It is shown that there exists a quench layer with steep temperature gradients inside the reactor; a great amount of ambient air is always entrained into the plasma reactor; and the flow direction of the entrained air, the location and shape of the quench layer are dependent on the momentum flux ratio of the plasma jet to the counter-injected cold gas. Two quite different flow patterns are obtained at higher and lower momentum flux ratios, and thus there exists a critical momentum flux ratio to separate the different flow patterns and to obtain the widest quench layer. There exists a high argon concentration or even ‘air-free’ channel along the reactor axis. No appreciable difference is found between the turbulent and laminar plasma reactors in their overall plasma parameter distributions and the quench layer locations, but the values of the critical momentum flux ratio are somewhat different.     

Effects of the Length of a Cylindrical Solid Shield on the Entrainment of Ambient Air into Turbulent and Laminar Impinging Argon Plasma Jets

When materials processing is conducted in air surroundings by use of an impinging plasma jet, the ambient air will be entrained into the materials processing region, resulting in unfavorable oxidation of the feedstock metal particles injected into the plasma jet and of metallic substrate material. Using a cylindrical solid shield may avoid the air entrainment if the shield length is suitably selected and this approach has the merit that expensive vacuum chamber and its pumping system are not needed. Modeling study is thus conducted to reveal how the length of the cylindrical solid shield affects the ambient air entrainment when materials processing (spraying, remelting, hardening, etc.) is conducted by use of a turbulent or laminar argon plasma jet impinging normally upon a flat substrate in atmospheric air. It is shown that the mass flow rate of the ambient air entrained into the impinging plasma jet cannot be appreciably reduced unless the cylindrical shield is long enough. In order to completely avoid the air entrainment, the gap between the downstream-end section of the cylindrical solid shield and the substrate surface must be carefully selected, and the suitable size of the gap for the turbulent plasma jet is appreciably larger than that for the laminar one. The overheating of the solid shield or the substrate could become a problem for the turbulent case, and thus additional cooling measure may be needed when the entrainment of ambient air into the turbulent impinging plasma jet is to be completely avoided.     

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.     

Air entrainment in an inductively coupled plasma measured by Raman and Rayleigh scattering

A new technique to study the entrainment of air into the inductively coupled argon plasma is presented. The combination of vibrational Raman scattering and Rayleigh scattering enables measuring absolute particle densities of air and argon. The measurements show the entrainment of air into the plasma. At an axial position of 2 mm above the end of the quartz torch it is found that at 90% of the plasma radius 55% of the particles originate from air and by exponential extrapolation towards 70% of the radius about 1% entrainment of air is predicted to be present. Furthermore, a comparison with a cold argon flow shows that due to the higher viscosity the entrainment in the plasma is lower than in the cold argon flow.     

Probe measurements in thermal plasma jets

Measurements of composition, temperature, and velocity in atmospheric argon plasma jets are reported, using enthalpy probes. The plasma jets are generated by a commercial type plasma gun and the measurements are expected to be of particular interest for industrial applications such as plasma spraying. Emphasis has been on the central and downstream regions of the plasma flame. The entrainment of air into the jet was found to be very high, even close to the axis of the jet. Gas samples analyzed with a gas chromatograph showed demixing of the air, i.e., nitrogen is more abundant in the jet than at room temperature. The high air entrainment has a strong cooling effect on the plasma, resulting in a rapid temperature drop along the axis. The influence of the argon flow rate and of the arc current on the jet's conditions was parametrically studied. Matching of the quantities measured in the jet with the torch input confirmed the validity of the results, and the relevance of enthalpy probe diagnostics in thermal plasma jets.     

Numerical Prediction of the Noise Emission from a Turbulent Argon Thermal-Plasma Jet Issuing into Ambient Air

This paper attempts to predict the noise emission characteristics of a turbulent argon thermal-plasma jet issuing into ambient air. The flow, temperature and concentration fields and turbulence characteristics of the turbulent plasma jet are computed at first, and then the noise emission from the plasma jet to a sideline far-field observer is calculated using the approach proposed by Fortuné and Gervais (AIAA J. 37(1999)1055) for predicting the noise emission from a turbulent, hot but non-ionized, air jet after some modification. The diffusion of ambient air into the turbulent argon plasma jet is handled using the turbulence-enhanced combined–diffusion-coefficient method. Velocity fluctuation correlations (aerodynamic noise source) in the plasma jet are calculated still using the K-ɛ two-equation turbulence model, but the temperature-velocity fluctuation correlations (entropic noise source) within the jet are calculated by solving a second-order turbulent Reynolds heat-flux transport equation in order to better deal with the contribution of temperature fluctuation to the noise emission. It is shown that among the contributions of aerodynamic noise source, entropic noise source and their mixed effect, the entropic noise source (i.e. the temperature-velocity fluctuation correlations) is dominant for the noise emission from the turbulent plasma jet to the sideline observer. The noise intensity increases with increasing plasma jet temperature or velocity. The predicted noise frequency spectrum characteristics and noise intensity levels are shown to be reasonably consistent with available experimental data.     

Improvement of plasma spraying efficiency and coating quality

A commercial torch has been modified to introduce an additional anti-vortex and shroud gas flow to counter the detrimental effects brought about by the vortex plasma gas flow which is used to stabilize the cathode arc attachment and to increase the anode life. Deposition efficiency and coating quality are used as criteria to judge the modified versus the nonmodified torch. High-speed videography and computerized image analysis systems are used to determine the particle trajectories, velocities, and the plasma jet geometry. The results show that the additional anti-vortex and shroud gas flow to the torch can keep the particles closer to the torch axis and reduce the amount of entrainment of cold air into the plasma jet. The consequence is that deposition efficiency and coating quality are substantially improved.     

Experimental Study on the Thermal Argon Plasma Generation and Jet Length Change Characteristics at Atmospheric Pressure

The generation, jet length and flow-regime change characteristics of argon plasma issuing into ambient air have been experimentally examined. Different torch structures have been used in the tests. Laminar plasma jets can be generated within a rather wide range of working-gas flow rates, and an unsteady transitional flow state exists between the laminar and turbulent flow regimes. The high-temperature region length of the laminar plasma jet can be over an order longer than that of the turbulent plasma jet and increases with increasing argon flow rate or arc current, while the jet length of the turbulent plasma is less influenced by the generating parameters. The flow field of the plasma jet has very high radial gradients of plasma parameters, and a Reynolds number alone calculated in the ordinary manner may not adequately serve as a criterion for transition. The laminar plasma jet can have a higher velocity than that of an unsteady or turbulent jet. The long laminar plasma jet has good stiffness to withstand the impact of laterally injected cold gas and particulate matter. It could be used as a rather ideal object for fundamental studies and be applied to novel materials processing due to its attractive stable and adjustable properties.     

Fundamental comparison between non-equilibrium aspects of ICP and MIP discharges

A characterization theory is constructed to relate external control parameters to averaged values of internal plasma properties. It is based on a study on the effect of transport fluxes on elementary balances. This theory is used to compare the inductively coupled plasma (ICP) with the TIA (`torche a injection axiale', a microwave plasma) and to predict properties of He plasmas. The theory is validated by means of laser experiments on the ICP and TIA. Thomson (TS), Rayleigh (RyS) and Raman (RnS) scattering are used to get insight into spatially resolved plasma parameters. TS gives the electron number density and temperature, whereas the combination of RyS and RnS provides the densities of (entrained) air molecules and argon atoms (main gas). In particular, the influence of steep gradients and the air entrainment turn out to be of crucial importance for those situations in which the characterization theory does not properly predict the values of plasma parameters.     

Entrainment of ambient air into a spectrochemical inductively coupled argon plasma

A spectrochemical inductively coupled argon plasma (ICP) is normally operated in the open air. Therefore, it is suggested in the literature that entrainment of air molecules into such an ICP may cause loss of electrons, especially so at the plasma's edge. The present study discusses the significance of this effect. The density and temperature of electrons and nitrogen molecules around the edge of the plasma were measured by Thomson and rotational Raman scattering. A region where both electrons and nitrogen were present in detectable amounts (10¹⁹ and 10²⁴ m⁻³, respectively) could not be observed. Above the torch inner wall the nitrogen concentration drops rapidly towards the plasma. Measurements suggest that the nitrogen concentration at 1 mm from the plasma is only a few percent, and in the active zones of the plasma (far) below 0.1%. This is not enough to affect the plasma significantly. Moreover, electron loss due to diffusion of nitrogen into the plasma is calculated to be much slower than the loss observed in earlier studies. Hence, air entrainment is unlikely to play a significant role in the ICP. A possible alternative is the formation and destruction of molecular rare gas ions.     

Generation of Long, Laminar Plasma Jets at Atmospheric Pressure and Effects of Flow Turbulence

Long, laminar plasma jets at atmospheric pressure of pure argon and a mixture of argon and nitrogen with jet length up to 45 times its diameter could be generated with a DC arc torch by restricting the movement of arc root in the torch channel. Effects of torch structure, gas feeding, and characteristics of power supply on the length of plasma jets were experimentally examined. Plasma jets of considerable length and excellent stability could be obtained by regulating the generating parameters, including arc channel geometry, gas flow rate, and feeding methods, etc. Influence of flow turbulence at the torch nozzle exit on the temperature distribution of plasma jets was numerically simulated. The analysis indicated that laminar flow plasma with very low initial turbulent kinetic energy will produce a long jet with low axial temperature gradient. This kind of long laminar plasma jet could greatly improve the controllability for materials processing, compared with a short turbulent arc jet.     

Computational fluid dynamics modeling of multicomponent thermal plasmas

A comprehensive computational model has been developed Jbr flowing thermal plasmas in the absence of electromagnetic fields, with particular emphasis on plasma jets. The plasma is represented as a rnulticomponent chemicalh, reacting ideal gas with temperature-dependent thermodynamic and transport properties. The plasma flow is governed by the transient compressible Navier-Stokes equations in two or three space dimensions. Turbulence is represented by subgrid-scale and k- models. Species diffusion is calculated by an effective binary diffusion approximation, generalized to allow /or ambipolar diffusion of charged species. Ionization, dissociation, recombination, and other chemical reactions are computed by general kinetic and equilibrium chemistry algorithms. Radiation heat loss is currently modeled as a temperature-dependent energy sink. Finite-difference approximations to the governing equations are solved on a rectangular spatial mesh using explicit temporal differencing. Computational inefficiency at low Mach number is avoided br reducing the effective sound speed. The overall computational model is embodied in a new computer code called LAVA. Computational results and comparisons with experimental data are presented Jbr LAVA simulations of a steady-stare axisymmetric argon plasma jet flowing into cold argon.     

Surface Modification of Poly-ε-Caprolactone with an Atmospheric Pressure Plasma Jet

In this work, poly-ε-caprolactone samples are modified by an atmospheric pressure plasma jet in pure argon and argon/water vapour mixtures. In a first part of the paper, the chemical species present in the plasma jet are identified by optical emission spectroscopy and it was found that plasmas generated in argon/0.05 % water vapour mixtures show the highest emission intensity of OH (A–X) at 308 nm. In a subsequent section, plasma jet surface treatments in argon and argon/water vapour mixtures have been investigated using contact angle measurements and X-ray photoelectron spectroscopy. The polymer samples modified with the plasma jet show a significant decrease in water contact angle due to the incorporation of oxygen-containing groups, such as C–O, C=O and O–C=O. The most efficient oxygen inclusion was however found when 0.05 % of water vapour is added to the argon feeding gas, which correlates with the highest intensity of OH (X) radicals. By optimizing the OH (X) radical yield in the plasma jet, the highest polymer modification efficiency can thus be obtained.     

Modeling of the cathode jet of a high-power transferred arc

A physical model of two zones (constricted arc and cathode jet) of a 1-MW transferred arc in air is presented. It is based on the solution al conservation equations by a finite-differenee method. Turbulence is treated with Prandtl's approximation, whereas radiative transfer is solved considering a nonhontogeneous medium, with the hypothesis of gray spectral bands. The in of radiative transfer on the temperature field is illustrated using two-band and four-band radiation models. We also show the influence of several parameters on plasma jet properties: current intensity between 500 and 1500 A; gas mass /low rate between 10 and 90g/s, vortex injection. The arc characteristics are analyzed in accordance with physical mechanisms such as heat conduction, radiation, turbulence, convection, and miring of cold gas.     

Unsteadiness and mixing in thermal plasma jets

This study was undertaken to examine the mechanisms which produce the large entrainment measured at the exit of thermal plasma torches. The experiments studied a Metco 7MB plasma torch with a 706 (6.35 mm diameter) anode nozzle and swirled argon gas injection. The vortex structure produced in the shear layer of the plasma jet was visualized using a laser shadowgraph system with a short exposure lime (10^–4 s). A high-speed video system provided information on the structure and unsteadiness of the hot potential core of the plume. Tile shear layer visualizations were compared to previous measurements of acoustical power spectra and indicate coherent vortex structure formation at low gas flowrates. At higher gas flowrates the shear layer rapidly broke down, producing relatively small scale turbulence. The visualizations of the hot potential core were compared to previous measurements of the torch voltage fluctuations caused by arc instabilities. At low flowrates the arc-produced voltage fluctuations were guile low card the phone was very steady. At higher flowrates the voltage fluctuations increased and produced surging and whipping in the hot potential core.     

Thermal Plasma Flow Modeling: A Simple Model for Gas Heating and Acceleration

A simple model of gas heating and acceleration in a plasma torch is proposed. With simple conditions, easy to get from the torch operating parameters, this model leads to apprehend the gas behavior interacting with the surrounding atmosphere outside the torch, in steady or unsteady state. To better apprehend the air introduction into the plasma flow, different values of the Schmidt number have been investigated according to a classic k–ε turbulence model. Comparisons between velocity, temperature and Nitrogen percentage measurements and calculations were made in steady state.     

Diagnostics of a thermal plasma jet by optical emission spectroscopy and enthalpy probe measurements

An accurate determination of electron density, temperature, and velocity distributions is of primary interest for the characterization of steady-state thermal plasma spray jets. Our diagnostic capabilities based on optical emission spectroscopy include measurements of absolute emission coefficients and Stark broadening. In addition, enthalpy probe diagnostics has also been used for temperature and velocity measurements. Observation of large discrepancies between temperatures derived from absolute emission coefficients, Stark broadening, and from enthalpy probe measurements indicate that severe deviations from LTE (local thermal equilibrium) exist in various regimes of plasma spray jets. Nonequilibrum characterization of such turbulent thermal plasma jets suggests that diffusion of high-energy electrons into the fringes of plasma jets and deviations from chemical equilibrium due to high velocities in the core of plasma jets and entrainment of cold gas, are the main reasons for these discrepancies. The establishment of a reliable data base, taking these nonequilibrium effects into account, is a prerequisite for meaningful modeling of real plasma jets.     

On air entrainment in coatings

A series of experiments that clarify how air bubbles become entrained into coatings are described. The contact line dynamics at the air-liquid interface surrounding a fiber is characterized for a typical coating die operating under atmospheric and pressurized conditions. Glycerin and other viscous liquids are used to reveal that a critical fiber speed exists at which air entrainment begins. The observations confirm that the critical capillary number Ca(c) depends on the physical properties of the coating material, in the form of the Morton number. When the liquid supply is pressurized, the experiments show that adjusting the pressure can stabilize the displaced free surface interface at a prescribed location. Controlling the meniscus location in this way eliminates air entrainment. The threshold occurs when the applied pressure balances the shear exerted on the coating by the moving fiber. Using this approach it is possible to eliminate air entrainment and attain stable wetting at very large values of the capillary number, e.g., Ca congruent with 50.