Numerical Simulation of Fluid Flow and Heat Transfer in a DC Non-Transferred Arc Plasma Torch Operating Under Laminar and Turbulent Conditions

In this work, a magnetic fluid dynamics (MHD) model is used to simulate the electromagnetic field, heat transfer and fluid flow in a DC non-transferred arc plasma torch under laminar and turbulent conditions. The electric current density, temperature and velocity distributions in the torch are obtained through the coupled iterative calculation about the electromagnetic equations described in a magnetic vector potential format and the modified fluid dynamics equations. The fluid-solid coupled calculation method is applied to guarantee the continuity of the electric current and heat transfer at the interface between the electrodes and fluid. The predicted location of the anodic arc root attachment and the arc voltage of the torch are consistent with corresponding experimental results. Through a specific analysis of the influence of mass flow rates and electric current on the torch outlet parameters, the total thermal efficiency, thermal loss of each part, and the laws of the variation of outlet parameters with the variation of mass flow rates and electric current was obtained. It is found that operation under a laminar condition with a limited area of the anode could increase the total thermal efficiency of the torch.     

Parametric Study on Arc Behavior of Magnetically Diffused Arc

A model coupling the plasma with a cathode body is applied in the simulation of the diffuse state of a magnetically rotating arc.Four parametric studies are performed:on the external axial magnetic field (AMF),on the cathode shape,on the total current and on the inlet gas velocity.The numerical results show that:the cathode attachment focuses in the center of the cathode tip with zero AMF and gradually shifts off the axis with the increase of AMF;a larger cathode conical angle corresponds to a cathode arc attachment farther away off axis;the maximum values of plasma temperature increase with the total current;the plasma column in front of the cathode tip expands more severely in the axial direction,with a higher inlet speed;the cathode arc attachment shrinks towards the tip as the inlet speed increases.The various results are supposed to be explained by the joint effect of coupled cathode surface heating and plasma rotating flow.     

Comparative analysis of the arc characteristics inside the converging-diverging and cylindrical plasma torches

A two-temperature thermal non-equilibrium model is used to simulate and compare the arc characteristics within the converging-diverging and traditional cylindrical plasma torches.The modeling results show that the presence of the constrictor within the converging-diverging torch makes the evolution characteristics of the arc significantly different from that of cylindrical torch.Compared with a cylindrical geometrical torch,a much higher plasma flow velocity and relatively longer high temperature region can be generated and maintained inside the converging-diverging torch.In the constrictor of converging-diverging torch,the normalized radius of arc column increases and the degree of thermodynamic equilibrium of the plasma is significantly improved with the increase of axial distance.The radial momentum balance analysis shows that for the cylindrical torch,the pressure gradient that drives the arc expansion and the Lorentz force that drives the arc contraction dominate the radial evolution of the arc.While at the converging and constrictor region of a converging-diverging plasma torch,the radial gas dynamic forces in arc fringes pointing toward the arc center enhance the mixing of the cold gas of boundary layer with the high temperature gas of the arc center,increasing the average gas temperature and decreasing the thickness of cold boundary layer,thereby facilitating the formation of diffusion type arc anode attachment at the diverging section of torch.     

阳极结构对直流非转移型等离子体射流特性的影响

本文介绍了自行研制的直流非转移弧等离子体炬的结构和工作原理,研究了不同阳极结构等离子体射流的特性与气体流量、弧功率的关系,以及侧向垂直送气对射流形貌的影响.结果表明,阳极结构对等离子体射流特性的影响较大,弧压随着阳极压缩角的增大而下降,较小压缩角的射流稳定性更好;通道直径较小的等离子体射流刚性更强;不同阳极结构的等离子体炬可以有不同的应用领域.     

磁驱动旋转电弧运动图像及弧电压脉动的实验研究

磁驱动旋转电弧产生扩散电弧等离子体过程中有许多有趣的物理现象。本文利用高速摄影技术研究了大气压条件下、非均匀磁场中、大尺度磁驱动旋转氩电弧的电弧结构；在一定的弧电流和外磁场条件下，电弧的平面形状表现为不断发展和增长的螺旋结构，电弧螺旋结构的破裂往往产生于阴极附近的等离子体射流。采用图像分析的方法计算了外部磁场作用下阳极斑点沿弧室内壁的移动频率，分析了磁驱动旋转电弧运动过程中的弧电压脉动现象。结合电弧图像分析和电弧电压脉动及其FFT分析得出：电弧电压的大幅波动与多层电弧螺旋结构破裂和重建相关，而电弧电压的小幅波动则是弧根小幅跳动引起电弧拉长和收缩的结果。     

Numerical simulation of the effects of protrusion on DC arc anode attachment

The attachment of the DC arc on the anode is usually affected by surface morphology such as protrusions due to ablation or melting deformation.A three-dimensional thermodynamic and chemical non-equilibrium model is used to numerically simulate the effect of artificially assumed surface protrusions on the arc anode attachment.The numerical simulation results show that the arc deflects toward the protrusions on the anode and attaches to them in a constricted mode,resulting in an increase in the temperature of the arc attachment region.The analysis shows that the presence of protrusion on the anode surface changes the electric field distribution,intensifies the degree of thermodynamic and chemical non-equilibrium in its vicinity,further influences the chemical kinetic process of the plasma around it,which is the main reason for the deflection of the arc toward the protrusions and the arc anode attachment in a constricted mode.In order to verify the numerical simulation results,verification experiments are also performed using similar size scale anode protrusion,and the results showed that the presence of protrusion can indeed cause the deflection of the arc and even cause the ablation of the protrusion.     

Investigation on Plasma Jet Flow Phenomena During DC Air Arc Motion in Bridge-Type Contacts

Arc plasma jet flow in the air was investigated under a bridge-type contacts in a DC 270 V resistive circuit.We characterized the arc plasma jet flow appearance at different currents by using high-speed photography,and two polished contacts were used to search for the relationship between roughness and plasma jet flow.Then,to make the nature of arc plasma jet flow phenomena clear,a simplified model based on magnetohydrodynamic (MHD) theory was established and calculated.The simulated DC arc plasma was presented with the temperature distribution and the current density distribution.Furthermore,the calculated arc flow vclocity field showed that the circular vortex was an embodiment of the arc plasma jet flow progress.The combined action of volume force and contact surface was the main reason of the arc jet flow.     

Design and characteristics of a triple-cathode cascade plasma torch for spheroidization of metallic powders

Arc plasma torch is an effective tool for spheroidization of metallic powders. However, as most conventional plasma torches were not specifically designed for plasma spheroidization, they may exhibit the disadvantages of the radial injection of powders, large fluctuations in the arc voltage, large gas flow rate, and disequilibrium between multiple plasma jets during the spheroidization process. Therefore, this paper presents a triple-cathode cascade plasma torch (TCCPT) for plasma spheroidization. Its structural design, including three cathodes, a common anode, and three sets of inter-electrodes, are detailed to ensure that powders can be inserted into the plasma jet by axial injection, the arc voltage fluctuations are easily maintained at a low level, and the plasma torches can work at a relatively small gas flow rate. Experimental results showed that the proposed TCCPT exhibits the following characteristics: (1) a relatively small arc voltage fluctuation within 5.3%; (2) a relatively high arc voltage of 75 V and low gas flow rate range of 10–30 SLM; (3) easy to be maintained at the equilibrium state with the equilibrium index of the three plasma jets within 3.5 V. Furthermore, plasma spheroidization experiments of SUS304 stainless steel powers were carried out using the proposed TCCPT. Results verified that the proposed TCCPT is applicable and effective for the spheroidization of metallic powders with wide size distribution.     

Characteristics of Single Cathode Cascaded Bias Voltage Arc Plasma

A single cathode with a cascaded bias voltage arc plasma source has been developed with a new quartz cathode chamber,instead of the previous copper chambers,to provide better diagnostic observation and access to the plasma optical emission.The cathode chamber cooling scheme is also modified to be naturally cooled only by light emission without cooling water to improve the optical thin performance in the optical path.A single-parameter physical model has been developed to describe the power dissipated in the cascaded bias voltage arc discharge argon plasmas,which have been investigated by utilizing optical emission spectroscopy(OES) and Langmuir probe.In the experiments,discharge currents from 50 A to 100 A,argon flow rates from 800 sccm to 2000 sccm and magnetic fields of 0.1 T and 0.2 T were chosen.The results show:(a) the relationship between the averaged resistivity and the averaged current density exhibits an empirical scaling law as η∝ j~(-0.63369) and the power dissipated in the arc has a strong relation with the filling factor;(b) through the quartz,the argon ions optical emission lines have been easily observed and are dominating with wavelengths between 340 nm and 520 nm,which are the emissions of Ar~+-434.81 nm and Ar~+-442.60 nm line,and theintensities are increasing with the arc current and decreasing with the inlet argon flow rate;and(c) the electron density and temperature can reach 2.0 × 10~(19) m~(-3) and 0.48 eV,respectively,under the conditions of an arc current of 90 A and a magnetic field of 0.2 T.The half-width of the n_e radial profile is approximatively equal to a few Larmor radii of electrons and can be regarded as the diameter of the plasma jet in the experiments.     

Improvement on Diamond Nucleation Treated by Pulsed Arc Discharge Plasma

A technique of improvement on diamond nucleation based on pulsed arc discharge plasma at atmospheric pressure was developed. The pulsed arc discharge was induced respectively by nitrogen, argon and methanol gas. After the arc plasma pretreatment, a nucleation density higher than 10^10 cm^-2 may be obtained subsequently in chemical vapor deposition (CVD) on a mirror-polished silicon substrate without any other mechanical treatment. The effects of the arc discharge plasma on the diamond nucleation were investigated by scanning electron microscopy (SEM), X-ray photoelectron spectroscopy (XPS), infrared spectroscopy (IR) and Raman spectroscopy. The enhancement of nucleation is postulated to be a result of the formation of carbonlike phase materials or nitrogenation on the substrate surface without surface defect produced by arc discharge.     

Numerical simulation of low-current vacuumarc jet considering anode evaporation in different axial magnetic fields

As the main source of the vacuum arc plasma, cathode spots (CSs) play an important role on the behaviors of the vacuum arc. Their characteristics are affected by many factors, especially by the magnetic field. In this paper, the characteristics of the plasma jet from a single CS in vacuum arc under external axial magnetic field (AMF) are studied. A multi-species magneto-hydro-dynamic (MHD) model is established to describe the vacuum arc. The anode temperature is calculated by the anode activity model based on the energy flux obtained from the MHD model. The simulation results indicate that the external AMF has a significant effect on the characteristic of the plasma jet. When the external AMF is high enough, a bright spot appears on the anode surface. This is because with a higher AMF, the contraction of the diffused arc becomes more obvious, leading to a higher energy flux to the anode and thus a higher anode temperature. Then more secondary plasma can be generated near the anode, and the brightness of the ‘anode spot’ increases. During this process, the arc appearance gradually changes from a cone to a dumbbell shape. In this condition, the arc is in the diffuse mode. The appearance of the plasma jet calculated in the model is consistent with the experimental results.     

Decomposition of Nitrogen Trifluoride Using Low Power Arc Plasma

The low power arc plasma is characterized by extremely high enthalpy and temperature and it is easy to generate and control,and thus thermal decomposition process based on the plasma torch is receiving a great attention for decomposing non-degradable greenhouse gases.In order to elevate the economic feasibility,the efects of input power,waste gas flow rate and additive gases on the destruction and removal efciency(DRE) of NF3 are examined.Specific energy density(SED) deceases as the flow rate increases,and accordingly,the DRE is reduced.The DRE is basically determined by the specific energy density.The highest DRE of NF3 was 97% for the waste gas flow rate of 100 L/min at a low input power level of 2 kW with the help of hydrogen additional gas.The inlet and outlet concentration of NF3 was analyzed using Fourier transform infrared spectroscopy(FT-IR) for DRE of NF3 evaluation.As a result,large amount of NF3 can be efciently decomposed by low power arc plasma systems.     

大气压下大功率等离子体炬的数值模拟

主要研究直流等离子体炬的数值模拟方法,通过求解等离子体弧社区域的能量守恒,动量守恒,质量守恒及电流连续性方程,得到不同边界条件下温度,速度,电流密度分布,计算了大气压下２００Ａ自由氩弧的温度分布,电势和电流分布,并与实验数据及现有的理论计算进行了比较,得到了较好的结果,在此基础上结合本实验室５０００Ａ大功率等离子体炬,讨论了有阴极喷口存在下的弧柱部分的数值计算,以及能量守恒方程中辐射项,焦耳热项的     

Dual Torch Plasma Arc Furnace for Medical Waste Treatment

In this paper, characteristics of a treatment and operated at atmospheric pressure dual torch plasma arc used for hazardous waste are studied, and also compared with those of the multi-torch plasma arc and the single torch plasma arc. The dual torch plasma arc is generated between the cathode and anode with argon as the working gas. The temperature distributions of the plasma arc are measured using a spectroscope and line pair method with the assumption of local thermodynamic equilibrium （LTE） for the DC arc current I=100 A and argon flow rate Q = 15 slpm. The measurements show that the temperatures of the dual torch arc plasma in the regions near the cathode, the anode and the center point are 10,000 K, 11,000 K and 9,000 K, respectively. And the high temperature region of the multi torch plasma arc is of double or much wider size than that of a conventional dual torch plasma arc and single plasma torch. Based on the preceding studies, a dual torch plasma arc furnace is developed in this study. The measured gas temperature at the center region of the argon arc is about 11,000 K for the case of I=200 A and Q=30 slpm operated in atmosphere.     

Particle flux characteristics of a compact high-field cascaded arc plasma device

A new compact cascaded arc device for plasma-wall interaction study is developed at the Institute of Plasma Physics,Chinese Academy of Sciences.A magnetic field up to 0.8 T is achieved to confine plasmas in a 1.2 m long and 0.1 m diameter vacuum chamber.Gas fluid type analysis in this compact vacuum system was done under high particle flux condition.The gas pressure obtained by calculation was consistent with the measurement result.Continuous argon plasma discharge with ion flux of～0.5×1024 m-2 s-1 is successfully sustained for more than 1 h.The effects of magnetic field configuration,gas flow rate,and discharge arc current on the ion flux to target were studied in detail.     

Study of double-chamber air arc plasma torch and the application in solid-waste disposal

Arc plasma can be applied in hazardous solid waste disposal for higher temperature than common heating methods, but some practical issues exist in practical engineering application. In this study, an air arc plasma torch with double chambers and magnetic controlling is designed to realize wide variable power and long electrode life. The detailed characteristics and laws of the air arc are studied. The condition parameters of arc current(I), air flow rate(G) and the structure parameters of inlet area ratios and electrode diameters influence both the arc voltage and arc root positions. The arc rotating driven by magnetic field effectively lengthens the electrode life. The gasification process and product of organic wastes by air plasma are influenced largely by the waste compositions and the air flow rate. A furnace structure with more even atmosphere and longer residence time should be considered for better gasification. Oxygen-deficient environment is important to suppress NOxformation during the application of air plasma. Inorganic solid wastes can be melt by the air plasma and cooled down to form compact vitreous structures in which heavy metals can be locked and the leaching rates significantly decrease down.     

Numerical simulation of constricted and diffusive arc–anode attachments in wall-stabilized transferred argon arcs

A numerical simulation is conducted to investigate arc–anode attachment behavior, especially the formation mechanism of the constricted arc attachment mode for the water-cooled anode of wall-stabilized transferred argon arcs. Argon molecular ions and the corresponding kinetic processes are included to the finite-rate chemistry model in order to capture the chemical nonequilibrium characteristics of the arc near the anode region. Modeling results show that constricted and diffusive arc–anode attachments can be self-consistently obtained at different arc currents while keeping other parameters unchanged. The dominant kinetic processes contributing to ionization and recombination in the arc center and fringes are presented. The results show that in arc fringes and the arc attachment region, molecular ion recombination plays an important role which leads to the rapid loss of electrons. The radial evolution of the production, loss and transport processes of electrons is further analyzed. It is found that for the constricted arc attachment mode, both the recombination and convection transport caused by the anode jet result in the loss of electrons at the arc fringes, which leads to the shrinkage of the arc column at the anode. The formation of the anode jet is due to the combined action of radial and axial Lorentz forces in the anode region.     

Nonequilibrium Atmospheric Pressure Ar/O2 Plasma Jet: Properties and Application to Surface Cleaning

In this study an atmospheric pressure Ar/O_2 plasma jet is generated to study the effects of applied voltage and gas flux rate to the behavior of discharge and the metal surface cleaning.The increase in applied voltage leads to increases of the root mean square(rms) current,the input power and the gas temperature.Furthermore,the optical emission spectra show that the emission intensities of metastable argon and atomic oxygen increase with increasing applied voltage.However,the increase in gas flux rate leads to a reduction of the rms current,the input power and the gas temperature.Furthermore,the emission intensities of metastable argon and atomic oxygen decrease when gas flux rate increases.Contact angles are measured to estimate the cleaning performance,and the results show that the increase of applied voltage can improve the cleaning performance.Nevertheless,the increase of gas flux rate cannot improve the cleaning performance.Contact angles are compared for different input powers and gas flux rates to search for a better understanding of the major mechanism for surface cleaning by plasma jets.     

Simulation of Low-Voltage Arc Plasma During Contact Opening Progress

This paper focuses on the simulation of the low-voltage arc with an opening contact. A controllable experiment setup with a rotating contact is designed to investigate the arc behaviour. Supported by the experiment, the phenomena of arc elongation and commutation in the case of rotating contact are simulated with the dynamic grid technique introduced. Under the given condition of the external magnetic field and the contact rotating velocity, the stagnation and rapid jump of two arc roots are observed by the calculated and experimental arc root displacement. The voltage of arc column can be divided into four phases and its sharp rising progress comes from the increase of the displacement difference between two arc roots in x direction.     

Simulation of the Effect of a Metal Vapor Arc on Electrode Erosion in Liquid Metal Current Limiting Device

The effect of arc plasma on electrode erosion in a liquid metal current limiter(LMCL)is studied.Based on a simplified two-dimensional magnetohydrodynamic model,the elongated GaInSn metal vapor arc and its contraction process in a liquid metal current limiter are simulated.The distributions of temperature,pressure and velocity of the arc plasma are calculated.The simulation results indicate that the electrode erosion is mainly caused by two high temperature gas jet flows arising from the pressure gradient,which is a result of the non-uniform arc temperature distribution.The gas flows,which act as jets onto the electrode surface,lead to the evaporation of the electrode material form the surface.A redesign structure of the electrode is proposed and implemented according to the analysis,which greatly increased the service life of the electrode.