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.     

Advances in Plasma Arc Cutting Technology: The Experimental Part of an Integrated Approach

The experimental part of an integrated approach to design and optimization of plasma arc cutting devices will be presented; in particular results obtained through diagnostics based on high speed imaging and Schlieren photography and some evidences obtained through experimental procedures. High speed imaging enabled to investigate start-up transition phenomena in both pilot arc and transferred arc mode, anode attachment behaviour during piercing and cutting phases, cathode attachment behaviour during start-up transient in PAC torches with both retract and high frequency pulse pilot arc ignition. Schlieren photography has been used to better understand the interaction between the plasma discharge and the kerf front. The behaviour of hafnium cathodes at high current levels at the beginning of their service life was experimentally investigated, with the final aim of characterizing phenomena that take place during those initial piercing and cutting phases and optimizing the initial shape of the surface of the emissive insert.     

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.     

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.     

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.     

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.     

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.     

Cutting of glass and fused silica capillaries

An investigation of techniques suitable for precision cutting of glass and fused silica capillary tubing has been carried out. Accurate trimming of capillary tubing is important when precision splitters and manifolds have to be made. Techniques employed for cutting optical fibers proved to be useful, and factors affecting the suface quality of the fracture are discussed. It was found to be difficult to obtain a square cut with a flat surface in the case of fused silica tubing. The best results were obtained when the tubing was scored with the edge of a broken silicon wafer before the fracture was accomplished. This technique allows precision cutting of glass tubing with an outer diameter of 100 μm or less.     

Transport of uranium free particles in a d.c. arc plasma burning in air at atmospheric pressure

The transport parameter ψ was calculated for the free particles of uranium in a d.c. arc plasma burning in air. Using the “wire method” the volatilization rate (Q_w), the total concentration of free particles (_nt), the axial velocity (_vj) of uranium particles and the plasma cross section (S) were measured. The transport parameter was calculated for cylindrical symmetry of the arc. The total particle concentration calculated by the wire method was compared to values obtained by absolute intensity measurements of ion and atom spectral lines of uranium. This led to an estimate of the molecular concentration of uranium in the d.c. arc plasma.     

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.     

OES Use and Vaporization Modeling for Fly-Ash Plasma Vitrification

Results are presented of optical emission spectroscopy (OES) application asa control tool to improve fly-ash plasma vitrification. A twin-torch plasmasystem has been used for the fly-ash processing, and a new OES method hasexamined metallic vapors above the melt. The method allows the study ofnonhomogeneous optically thin plasmas exhibiting a symmetry plane withoutsophisticated tomographic systems. The dc arc torches are mounted above acold crucible filled with a synthetic glass. The arc intensity is from200 to 400 . Argon is introduced into the torches along the cathodeand the anode, while argon, oxygen or hydrogen are injected through thelance between the torches. Local plasma temperatures above the melt havebeen evaluated using measured relative intensities of spectral lines ofthe plasma-forming gas. Metallic vapor concentration in the plasma isdeduced from the intensity ratio of the metal–gas spectral lines. Leadoxide has been used to study heavy-metal behavior at the fly-ash plasmavitrification. Distribution of the lead along the crucible surface,depending on the plasma-forming gas composition as well as the concentrationevolution with time, have been examined. The elemental analysis of theresultant glass has been measured by scanning electron microscopy (SEM)with energy-dispersive spectrometry (EDS). A predictive model has beenadapted to simulate the noncongruent vaporization of heavy metals from themelt. According to the data obtained, steep variations of the volatility ofthe elements depend strongly on reducing properties of gases controllingthe plasma composition near the melted surface. In addition, the melttemperature and the redox potential of the gas phase are found to be themost critical parameters.     

MD Simulation of Effect of Crystal Orientation and Cutting Direction on Nanometric Cutting Using AFM Pin Tool

"Three-dimensional molecular dynamics simulations of nanometric cutting monocrystalline copper using atomic force microscopy pin tool are conducted to investigate the effect of crystal orientation and corresponding cutting direction on the deformation characteristics. EAM potential and Morse potential are utilized respectively to compute the interactions between workpiece atoms, interactions between workpiece atoms and tool atoms. The results reveal that the nanometric cutting processes are significantly affected by crystal orientation and cutting direction. Along the 110 cutting direction, better quality of chip pattern and smaller workpiece material deformation region can be obtained than along the 100 cutting direction. Cutting the workpiece material (110) crystal orientation, samaller chip volume and smaller subsurface deformed region can be obtained than cutting the workpiece material (100) crystal orientation. The variations of workpiece atoms potential energy in different cutting processes are investigated."     

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.     

Steam Torch Plasma Modelling

Numerical modelling of physical properties and processes in an electric arc stabilized by a water vortex (steam torch) has been summarized in this review paper. One-fluid MHD equations are numerically solved for an axisymmetric thermal plasma flow inside a discharge chamber of the steam plasma torch. The steady state solution results are discussed for the range of currents 300–600 A with relatively low steam flow rate of about 0.3 g s^?1. The maximum obtained velocities and temperatures—8500 m s^?1, 26,300 K, are reported at the centre of the nozzle exit for 600 A. The evaporation of water, i.e. mass flow rate of steam, was predicted from a comparison between the present simulation and experiments. The generated plasma is mildly compressible (M < 0.7) with the inertial forces overwhelming the magnetic, viscous, centrifugal and Coriolis forces with the factor of 10³. Our calculations showed that the most significant processes determining properties of the arc are the balance of the Joule heat with radiation and radial conduction losses from the arc. Rotation of plasma column due to the tangential velocity component has a negligible effect on the overall arc performance, however, the rotation of water induces fluctuations in the arc and in the plasma jet with characteristic frequency which is related to the frequency of rotation of water. Reabsorption of radiation occurs at the radial position higher than 2.5 mm from the arc axis. The amount of reabsorbed radiation is between 17 and 28%. LTE conditions are satisfied in the arc column with the 2 mm radius. Comparison between the present simulations and experiments shows good agreement with the current–voltage characteristics, radial velocity and temperature profiles, as well as with the other related numerical simulation.     

A Density Functional Study of the Nonlinear Optical Properties of Edge‐Functionalized Nonplanar Nanographenes

The atomically precise edge chlorination of nanographenes has recently been reported as a crucial technology of functionalization through which the planar structure and optical properties of nanographenes can be significantly changed. To check the effects of molecular size, geometrical symmetry and edge functionalization of nanographenes on their optical properties, a series of nanographenes is studied in the framework of density functional theory with the B3LYP functional. Our results indicate that edge functionalization remarkably changes the nonlinear optical properties and increases the anisotropy of nanographenes compared to the effects of the molecular size and system geometric symmetry. Furthermore, the nonlinear optical properties of nanographenes can be tuned by precise edge functionalization, which opens a new avenue for using nanographenes as nonlinear optical materials.     

Characterization of a twin-torch transferred dc arc

The results of a twin-torch transferred de arc .study are presented. The arc system consists of two torches of opposite polarity, and a coupling zone of plasma jets located between them. The torch configuration increases the system reliability and efficiency during material plasma processing. The results of the study present data for the voltage-current characteristics, general behavior of the twin-torch arc, and spatial distribution of the plasma parameters. The plasma parameters have been measured using optical emission spectroscopy for a 200 A (20 k W) do arc, at atmospheric pressure, with argon and nitrogen introduced as plasma forming gases into the anode and the cathode units, respectively. The measurement technique used has allowed the determination of local electron density and temperature values in an inhomogeneous plasma volume having no axial sysmmetry. The data obtained illustrate the novel features of the twin-torch transfrred do arc for its applications in plasma processing.     

The Dependence of Gliding Arc Gas Discharge Characteristics on Reactor Geometrical Configuration

The dependence of gliding arc gas discharge characteristics, including gas flow field, arc column motion and volatile organic compounds (VOCs) decomposition performance, on reactor configuration parameters was investigated based on numerical simulation and laboratory experimental findings. For a given supply voltage (10 kV) and a certain nozzle outlet diameter (1.5 mm), increasing the electrodes gap (1–4 mm) or decreasing vertical distance between electrode throat and nozzle outlet (25–10 mm) will increase the gas flow rate through the electrode throat, the gas velocity in the plasma region, the arc column velocity, the maximum attainable position of the arc column and the electrical power consumption, also, higher VOCs decomposition rate and lower specific energy requirement are observed according to the n-butane and toluene decomposition experiments.     

Some Cutting Oil Formulations Based on Local Prepared Emulsifiers Part I: Preparation of Some Emulsifiers Based on Local Raw Materials to Stabilize Cutting Oil Emulsions

The first main target of this work is to synthesis some emulsifiers from local raw materials used for cutting oil formulations. Seventeen emulsifiers (15 nonionic and 2 anionic) were prepared from locally available materials such as linear alkyl benzene sulfonic acid (LABSA), glycerol, polyethylene glycol, and maleic anhydride. Their chemical structures were confirmed using FTIR. The surface tension for the emulsifiers was measured at 25°C, and the surface and thermodynamic properties were calculated based on the surface tension parameters. The formulations of cutting oil fluids were prepared using these emulsifiers. The second target is to investigate the stability of soluble oil blends and emulsion stability of soluble oil in water. The results are discussed in the light of surface‐active properties and chemical structure of emulsifiers.     

Stability, electronic and magnetic properties of embedded triangular graphene nanoflakes

Stability, electronic and magnetic properties of triangular graphene nanoflakes embedded in graphane (graphane-embedded TGNFs) are investigated by density functional theory. It is found that the interface between the embedded TGNF and graphane is stable since the diffusion of H atoms from the graphane region to the embedded TGNF is energetically unfavorable with high energy barriers. The electronic and magnetic properties of the system completely depend on the embedded TGNF. The band gaps of graphane-embedded ATGNFs (armchair-edged TGNFs) arise due to the quantum confinement, while the special characteristics of nonbonding states of graphane-embedded ZTGNFs (zigzag-edged TGNFs) play an important role in their electronic properties. As the edge sizes increase, the differences of band gaps between graphane-embedded TGNFs and the isolated ones decrease. Furthermore, owing to the partially paired p(z) orbitals of edge C atoms, graphane-embedded ZTGNFs exhibit a ferrimagnetic ground state with size-dependant total spin being consistent with Lieb's theorem. Our work provides a possible way to obtain TGNFs without physical cutting.