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.     

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     

Numerical simulation for the characterization of operating conditions of RF-RF hybrid plasma torches

A two-dimensional (r,z) numerical code has been developed to investigate the prominent features of RF-RF hybrid plasma torches with two stages of different diameter. Flow and temperature fields have been calculated within the assumptions of laminar flow and local thermodynamic equilibrium for the optically thin argon plasma operated at atmospheric pressure, taking into full account the electromagnetic interaction between the primary and the secondary stage of the hybrid device. Results from a detailed parametric study for various geometric, gas flow and electric configurations aim at putting into evidence the wide range of operating conditions that can characterize the use of RF-RF hybrid plasma torches for industrial applications, showing also their possibility to give high enthalpy plasma jets with high torch efficiencies. The magnetofluidynamic modelling described in this work can be an effective tool for providing the theoretical framework for a deep understanding of RF-RF hybrid plasma torches and for designing them as suitable sources for chemical processing of materials, when utilized within an integrated approach that would match the induction plasma torch simulation with the RF generator operating conditions to evaluate the total source efficiency for each particular hybrid configuration.Received: 23 December 2003, Published online: 10 February 2004PACS: 52.75.Hn Plasma torches - 52.65.-y Plasma simulation - 52.80.Pi High-frequency - RF dischargesA colour version of the figures is available in electronic form at http: //ww.edpsciences.org     

Study of operating conditions of plasma spray torch using lowelectric power levels

The scaling-down of plasma spray torches is connected with problems of anodic arc attachment fluctuations. It Is known that thermally constricted arcs in molecular gases generate unstable anodic arc roots in the nozzle of the torch. Moreover, using a usual plasma spray torch at reduced electrical power level in an argon-hydrogen gas mixture at a pressure of about 120 mbar, the arc is strongly influenced by hydrodynamic forces. Especially, its long time behavior shown by the arc voltage course is very variable and nonreproducible. It is the purpose of this work to optimize the nozzle geometry and the gas flow rate in order to obtain stabilized operating conditions of the plasma torch for an arc current of 100 A. It will be shown that the design of the entrance region and the diameter of the anodic nozzle influence the are column motion as well as the level and the frequency of the voltage fluctuations. With a particularly modified anodic nozzle, stable and reproducible operating conditions of the plasma torch, which is used to synthesize diamond layers, will be obtained     

Arc plasma devices: Evolving mechanical design from numerical simulation

Wide ranges of technological applications involve arc plasma devices as the primary plasma source for processing work. Recent findings exhibit the existence of appreciable thermal non-equilibrium in these so-called thermal plasma devices. Commercially available magnetohydrodynamic codes are not capable of handling such systems due to unavailability of non-equilibrium thermodynamic and transport property data and self-consistent models. A recipe for obtaining mechanical design of arc plasma devices from numerical simulation incorporating two-temperature thermal non-equilibrium model is presented in this article with reference to the plasma of the mixture of molecular gases like nitrogen and oxygen. Such systems are technologically important as they correspond to the plasma devices operating with air, oxygen plasma torches in cutting industries and plasma devices using nitrogen as shielding gas. Temperature field, associated fluid dynamics and electrical characteristics of a plasma torch are computed in a systematic manner to evaluate the performance of a conceived design using a two-fluid CFD model coupled with a two-temperature thermodynamic and transport property code. Important effects of different nozzle designs and plasma gases obtained from the formalism are discussed. Non-equilibrium thermodynamic properties are computed using modified two-temperature Saha equations and transport properties are computed using standard Chapman–Enskog approach.     

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     

Simulation study of a capacitively coupled plasma torch array

Using capacitively coupled electrical discharges, an array of three plasma torches powered by a single 60-Hz source are lit up simultaneously to produce a dense plasma in the open air. The discharge voltage and current of each torch is measured for three cases of one to three torches being lit up in the array. The results determine the ν-i characteristic of the discharge which indicates that the torch is operating in a diffuse are mode. The torch array is modeled by an equivalent circuit for simulating its operation. The simulation results of the discharge voltage and current of a torch are shown to agree well with those from the experimental measurements for the three cases. The lump circuit model is then used to carry out numerical simulations of the discharge for a broad parameter space of plasma species. By fitting the simulation results, a function giving the parametric dependence of the consumed average power density 〈P〉 on the normalized average electron density 〈n_e〉 maintained in the plasma is determined to be 〈P〉 48 〈n_e〉 ^1.9α_^0.4(W/cm³), where 〈n_e〉 is normalized to 10¹³cm^-3 and α_, the electron-ion recombination coefficient normalized to 10^-7 cm³·s^-1, is used as a variable parameter in the simulation     

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     

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.     

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.     

Plasma torches and electrophysical parameters of the diaphragm discharge in water

This work is aimed at studying plasma torch formation, voltages, currents, power distribution, and resistance variation in the case of the little understood low-energy (≤10 J) diaphragm discharge initiated in water and salt solutions. Plasma torches associated with this type of discharge differ considerably from those of other discharges. Different shapes of anode and cathode torches, breakdowns between the diaphragm and one of the electrodes, and a specific form of cathode breakdown are observed. It is found that the electrical conductivity of the medium influences the parameters of the plasma formations, current pulses, dielectric strength of the medium, current pulse variation at “semibreakdowns,” etc. Based on the experimental data, it is concluded that the process of discharge initiation differs from that described in the literature.     

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。     

CaO–MgO–SiO2 glass ceramics: Transferred arc plasma (TAP) synthesis and microstructural characterization

In this paper, synthesis of CaO–MgO–SiO₂ glass ceramic using transferred arc plasma (TAP) processing method is illustrated. Homogeneous mixture of 51.6% SiO₂, 35.6% CaO and 12.8% MgO prepared by dry mixing in a ball mill was kept in the anode well (which is the melting bed) of the 10 kW transferred arc plasma torch. It was melted in plasma at an operating power of 5 kW (by varying the processing time for 3, 5 and 8 min). The melt was cooled to solidify by applying forced air on it. The resulting samples were characterized for microstructure and phase composition. The phases were identified by scanning electron microscopy (SEM), using the back-scattered electron (BSE) image mode and X-ray diffraction (XRD) and energy dispersive X-ray analysis (EDX). The microstructure was examined using optical microscopy (OM) and scanning electron microscopy. The micro-hardness, density and porosity measurements for the synthesized samples were carried out. Differential thermal analysis (DTA) was performed to study the thermal evolution. The results show the formation of diopside phase in the transferred arc plasma melted CaO–MgO–SiO₂ glass ceramic system achieved with in a quite considerable short time of plasma processing. The method indicated that TAP technique could be a promising, time saving and one-step manufacturing process for the production of functional bulk glass ceramics.     

Estimation of dynamic properties of attractors observed in hollow copper electrode atmospheric pressure arc plasma system

Understanding of the basic nature of arc root fluctuation is still one of the unsolved problems in thermal arc plasma physics. It has direct impact on myriads of thermal plasma applications being implemented at present. Recently, chaotic nature of arc root behavior has been reported through the analysis of voltages, acoustic and optical signals which are generated from a hollow copper electrode arc plasma torch. In this paper we present details of computations involved in the estimation process of various dynamic properties and show how they reflect chaotic behavior of arc root in the system.     

Arc Root Attachment on the Anode Surface of Arc Plasma Torch Observed with a Novel Method

The arc-root attachment on the anode surface of a dc non-transferred arc plasma torch has been successfully observed using a novel approach. A specially designed copper mirror with a boron nitride film coated on its surface central-region is employed to avoid the effect of intensive light emitted from the arc column upon the observation of weakly luminous arc root. It is found that the arc-root attachment is diffusive on the anode surface of the argon plasma torch, while constricted arc roots often occur when hydrogen or nitrogen is added into argon as the plasma-forming gas.     

Influence of processing variables on the formation of La2Zr2O7 in transferred arc plasma torch processing

The transferred arc plasma (TAP) torch process has various noteworthy features such as extremely high temperatures, low environmental impact and short processing time which makes it the most suitable technique for synthesizing ceramic composite materials. Furthermore, it is a direct two-step technique which by its virtue of high temperature and power density paves way for high production rate. Hence in this study, an effort has been made to utilize the TAP torch processing technique for the bulk production of La₂Zr₂O₇ with time effectiveness from the mixture of La₂O₃ and ZrO₂ powders (1:2 mol ratios) which were ball milled for 4 h. For this purpose, transferred arc plasma torch was specially designed in laboratory scale level and the operating parameters were optimized in order to achieve maximum La₂Zr₂O₇ formation efficiency. In this study, the phase and microstructure formation of the processed samples was analyzed via X-ray diffraction (XRD) and scanning electron microscope (SEM) images respectively. Moreover, EDX analysis was incorporated to highlight the superior influence of the longer processing time on the stoichiometric ratio of ZrO₂/La₂O₃ in the processed sample as against input power and the gas flow rate.     

Three-dimensional modelling of inductively coupled plasma torches

A three-dimensional model has been developed for simulating the behaviour of inductively coupled plasma torches (ICPTs), using customized CFD commercial code FLUENT ^?. The helicoidal coil is taken into account in its actual 3-D shape, showing the effects of its non-axisymmetry on the plasma discharge. Steady state, continuity, momentum and energy equations are solved for argon optically thin plasmas under the assumptions of LTE and laminar flow. The electromagnetic field is obtained by solving the 3-D vector potential equation on a grid extending outside the torch region. In order to evaluate the importance of various 3-D effects on calculated plasma temperature and flow fields, comparisons of our new results with the ones obtainable from conventional 2-D models and from an improved 2-D model that includes 3-D coil effects are presented. The presence of wall temperature hot spots due to plasma discharge displacement from the torch axis is evidenced, while the use of the new 3-D code for optimization of induction coil geometry and plasma gas inlet features is foreseen. Received 5 September 2002 Published online 13 December 2002 RID="a" ID="a"e-mail: colombo@ciram.ing.unibo.it     

层流等离子体制备球形氧化铝粉末的实验研究

为研究非转移弧层流等离子体制备面向新材料领域的μm级球形氧化铝粉末的能力,使用自制的非转移弧分段式阳极层流等离子体球化设备,以载气送粉的方式,对η相的不规则μm级三氧化二铝粉末进行等离子体球化处理,并采用均匀设计法,研究等离子体发生器和送粉器不同的工作参数对氧化铝粉末球化率的影响规律。结果表明,实验所采用的直流非转移弧层流等离子体发生器能有效制备球化率接近100%的高球化率球形氧化铝粉末。实验发现,高球化率、高分散性和粒径大小均匀的球形氧化铝粉末可在不同工艺参数组合下制备,并证明了采用非转移弧分段式阳极层流等离子体发生器可实现较低功率下制备较高球化率球形氧化铝的可行性。实验还通过XRD与PDF卡片索引技术对球化前后的氧化铝粉末进行了物相定性分析,发现η相的氧化铝粉末经射流作用转化成了Corundum型的氧化铝粉末。     

Experimental observation and numerical analysis of arc plasmas diffused by magnetism

At atmospheric pressure, an intensified charge-coupled device (ICCD) camera with a narrow-band filter is used to capture the unsaturated images of a magnetically rotating arc. Comparison of its configurations with different arc current and external axial magnetic field (AMF) strength shows that the strong electromagnetic force may impel the arc to diffuse. Under the fully diffuse mode, the plasma is distributed throughout the electrode gap and no anode attachment can be seen in the cross-section of the torch. The fully diffuse plasma runs more steadily and its intensity distribution is more uniform, while its voltage fluctuation is reduced significantly. Using a commercial CFD (computational fluid dynamics) code FLUENT, the fluid flow and heat transfer of the fully diffuse plasma in an assumed magnetron torch have been simulated for qualitatively discussing the AMF effects. Numerical results show that the AMF significantly impels the plasma to retract axially and expand radially. As a result, the plasma intensity distribution on the cross section of the torch gets to be more uniform.