Self-Consistent Cathode–Plasma Coupling and Role of the Fluid Flow Approach in Torch Modeling

A two-dimensional and stationary magnetohydrodynamic model of a plasma spray torch operated with argon is developed to predict the plasma properties in a steady operating mode. The model couples a submodel of a refractory cathode and its non-equilibrium boundary layer to a submodel of the plasma in local thermodynamic equilibrium in a self-consistent manner. The Navier–Stokes equations for a laminar and compressible flow are solved in terms of low and high Mach number numerical approaches. The results show that the Mach number can reach values close to one. Simulations are performed for electric currents of 600 A and 800 A, and gas flow rates of 40, 60, and 80 NLPM. The plasma parameters obtained by the two approaches differ, and the differences become more pronounced for higher currents and gas flow rates. The arc voltage, the electric power, and the thermal efficiency from both the low and high Mach number models of the plasma agree well with experimental findings for a current of 600 A and a flow rate of 40 NLPM. For higher currents and gas flow rates, the results of the low and high Mach number models gradually differ and underline the greater appropriateness of the high Mach number model

Effect of a Spatially Fluctuating Heating of Particles in a Plasma Spray Process

The work is concerned with the effect of a spatially fluctuating heating of Al2O3 particles with diameters of 5–120 μm during a plasma spray process. A plasma jet is generated in a mixture of Ar (40 NLPM) and H2 (14 NLPM) and in pure Ar at an electric current of 600 A. The tracing of the injected particles in the plume region of the plasma jets is considered in the framework of a three-dimensional model taking into account a turbulent fluid flow. It is shown that the heat source for the injected particles exhibits a well pronounced spatially fluctuating structure due to the enhancement of the thermal conductivity resulting from dissociation and ionization of the molecular gas in the temperature range of 2500–4000 K and 13,000–14,000 K, respectively. During their travel towards the substrate, the particles are therefore repeatedly heated in the gas mixture in contrast to the case of pure argon. Particles injected in the gas mixture reach the substrate with a higher average temperature and velocity

Modelling and experimental evidence of the cathode erosion in a plasma spray torch

The lifetime of tungsten cathodes used in plasma spray torches is limited by processes leading to a loss of cathode material. It was reported in the literature that the mechanism of their erosion is the evaporation. A model of the ionization layer of a cathode is developed to study the diffusive transport of evaporated tungsten atoms and tungsten ions produced due to ionization by electron impact in a background argon plasma. It is shown that the Stefan-Maxwell equations do not reduce to Fick law as one could expect for the transport of diluted species, which is due to significant diffusion velocities of argon ions. The ionization of tungsten atoms occurs in a distance of a few micrometers from the cathode surface and leads to a strong sink, which increases the net flux of tungsten atoms far beyond that obtained in absence of tungsten ions. This shows that the tungsten ions are driven by the electric field towards the cathode resulting in no net diffusive flux and no removal of tungsten species from the ionization layer even if convection is accounted for. A possible mechanism of removal is found by extending the model to comprise an anode. The extended model resolves the inter-electrode region and provides the plasma parameters for a current density corresponding to the value at the center of the cathode under typical arc currents of 600 A and 800 A. The presence of the anode causes a reversal of the electric field on the anode side, which pulls the ions away from the ionization layer of the cathode. The net flux of tungsten ions can be further fortified by convection. This model allows one to evaluate the loss of cathode material under realistic operating conditions in a quantitative agreement with measured values

Plasma Spraying of Kaolinite for Preparing Reactive Alumino-Silicate Glass Coatings

Thermally treated kaolinite is used to develop a range of alumino-silicate-based precursor materials but its behavior during plasma spraying has not been well-researched. In this study, two types of kaolinite samples were investigated in the form of low defect (KGa-1b) and high defect (KGa-2) varieties. The extreme temperatures of the plasma stream (up to 20 000 K) induced flash melting to produce a highly porous alumino-silicate glass without any crystallization of new Al−Si oxide minerals. The glass is comprised largely of intact or deformed spheres (average diameters 1.14–1.44 μm), which indicates rapid quenching and solidification before impact. The subspherical structures contain up to 40 % closed pore space caused by the rapid escape of water during melting. The low-density, porous alumino-silicate glass coatings with predicted specific surface areas (>0.95 m2/g) and hardnesses >1.8 GPa represent a potentially reactive but physically stable substrate ideal for further chemical functionalization

Modelling and experimental evidence of the cathode erosion in a plasma spray torch

The lifetime of tungsten cathodes used in plasma spray torches is limited by processes leading to a loss of cathode material. It was reported in the literature that the mechanism of their erosion is the evaporation. A model of the ionization layer of a cathode is developed to study the diffusive transport of evaporated tungsten atoms and tungsten ions produced due to ionization by electron impact in a background argon plasma. It is shown that the Stefan–Maxwell equations do not reduce to Fick law as one could expect for the transport of diluted species, which is due to significant diffusion velocities of argon ions. The ionization of tungsten atoms occurs in a distance of a few micrometers from the cathode surface and leads to a strong sink, which increases the net flux of tungsten atoms far beyond that obtained in absence of tungsten ions. This shows that the tungsten ions are driven by the electric field towards the cathode resulting in no net diffusive flux and no removal of tungsten species from the ionization layer even if convection is accounted for. A possible mechanism of removal is found by extending the model to comprise an anode. The extended model resolves the inter-electrode region and provides the plasma parameters for a current density corresponding to the value at the center of the cathode under typical arc currents of 600 A and 800 A. The presence of the anode causes a reversal of the electric field on the anode side, which pulls the ions away from the ionization layer of the cathode. The net flux of tungsten ions can be further fortified by convection. This model allows one to evaluate the loss of cathode material under realistic operating conditions in a quantitative agreement with measured values.info:eu-repo/semantics/publishedVersio

Synthesis of hydroxy-sodalite/cancrinite zeolites from calcite-bearing kaolin for the removal of heavy metal ions in aqueous media

A hydroxy-sodalite/cancrinite zeolite composite was synthesized from low-grade calcite-bearing kaolin by hydrothermal alkali-activation method at 160 °C for 6 h. The effect of calcite addition on the formation of the hydroxy-sodalite/cancrinite composite was investigated using artificial mixtures. The chemical composition and crystal morphology of the synthesized zeolite composite were characterized by X-ray powder diffraction, infrared spectroscopy, scanning electron microscopy, and N2 adsorption/desorption analyses. The average specific surface area is around 17–20 m2·g−1, whereas the average pore size lies in the mesoporous range (19–21 nm). The synthesized zeolite composite was used as an adsorbent for the removal of heavy metals in aqueous solutions. Batch experiments were employed to study the influence of adsorbent dosage on heavy metal removal efficiency. Results demonstrate the effective removal of significant quantities of Cu, Pb, Ni, and Zn from aqueous media. A comparative study of synthesized hydroxy-sodalite and hydroxy-sodalite/cancrinite composites revealed the latter was 16–24% more efficient at removing heavy metals from water. The order of metal uptake efficiency for these zeolites was determined to be Pb > Cu > Zn > Ni. These results indicate that zeolite composites synthesized from natural calcite-bearing kaolin materials could represent effective and low-cost adsorbents for heavy metal removal using water treatment devices in regions of water shortage

Energy Flux Characterisation of Atmospheric Pressure Plasma Spray Torches with Passive Thermal Probes

Passive thermal probes were applied on two different plasma spraying devices to gain a detailed understanding of the energy flux towards the substrate under atmospheric pressure. The challenge of very high thermal load was solved by using an advanced time-resolved measuring and evaluation technique. The combination with a controlled movement of the jets allowed to obtain insightful radial profiles. The energy flux to the substrate changes linearly to the electrical input power. When adding diatomic gases (H2/N2) to the gas mixture the energy flux increases significantly, suggesting a more efficient energy transport. For increasing the axial distance, the energy flux shows a quadratic reduction. The obtained radial profiles are exemplarily utilized to show the inhomogeneous effect of powder injection on the energy flux distribution