Effect of matrix thermal properties on laser-induced plasma

The matrix thermal properties have an important impact on laser-induced plasma,as the thermal effect dominates the interaction between ns-pulsed laser and matter,especially in metals.We used a series of pure metals and aluminum alloys to measure plasma temperature and electron density through laser-induced breakdown spectroscopy,in order to investigate the effect of matrix thermal properties on laser-induced plasma.In pure metals,a significant negative linear correlation was observed between the matrix thermal storage coefficient and plasma temperature,while a weak correlation was observed with electron density.The results indicate that metals with low thermal conductivity or specific heat capacity require less laser energy for thermal diffusion or melting and evaporation,resulting in higher ablation rates and higher plasma temperatures.However,considering ionization energy,thermal effects may be a secondary factor affecting electron density.The experiment of aluminum alloy further confirms the influence of thermal conductivity on plasma temperature and its mechanism explanation.

Effects of Diamond on the Mechanical Properties and Thermal Conductivity of Si_(3)N_(4)Composites Fabricated Using Spark Plasma Sintering

Micrometer-sized diamonds were incorporated into silicon nitride(Si_(3)N_(4))matrix to manufacture high-performance Si_(3)N_(4)-based composites using spark plasma sintering at 1500℃under 50 MPa.The effects of the diamond content on the phase composition,microstructure,mechanical properties and thermal conductivity of the composites were investigated.The results showed that the addition of diamond could effectively improve the hardness of the material.The thermal conductivity of Si_(3)N_(4)increased to 52.97 W/m·k at the maximum with the addition of 15 wt%diamond,which was 27.5%higher than that of the monolithic Si_(3)N_(4).At this point,the fracture toughness was 7.54 MPa·m^(1/2).Due to the addition of diamond,the composite material generated a new substance,MgSiN2,which effectively combined Si_(3)N_(4)with diamond.MgSiN2 might improve the hardness and thermal conductivity of the materials.

Effect of TiO_2 content on properties of Al_2O_3 thermal barrier coatings by plasma spraying

Al2O3 thermal barrier coatings with different TiO2 contents were deposited on 6061 aluminum alloy by plasma spraying. The corrosion resistance, thermal insulation property and phase composition of these coatings were investigated. The results indicate that all the feedstock powders exhibit phase transformation during the spray process. With the increase of the TiO2 content in the powder, the corrosion resistance of the coating is enhanced but the thermal insulation property is decreased. This can be attributed to the higher thermal conductivity but lower melting point and brittleness of TiO2 than those of Al2O3, so it is easy for TiO2 to disperse in the brittle Al2O3 substrate during spraying, in which these dispersively distributed TiO2 play the role of hole sealing, releasing stress and reducing cracks.

Production of pig iron from red mud waste fines using thermal plasma technology

Red mud, an insoluble residue produced during alkali leaching of bauxite, is considered as a low-grade iron ore containing 30% to 50% iron. The present paper deals with the use of thermal plasma technology for producing pig iron from red mud waste fines. The smelting reduction of red mud was carried out in a 35 kW DC extended arc thermal plasma reactor. Red mud was properly mixed with fluxes and graphite （fixed carbon, 99%） as a reductant as per stoichiometric requirement. The effect of various process parameters like a reductant, fluxes and smelting time on iron recovery was studied and optimized. An optimum condition for the maximum recovery of iron was obtained. A new thermal plasma process applicable to direct iron making from red mud waste fines that would achieve significant utilization of red mud was proposed.

Effect of sintering temperature on the microstructure and thermal conductivity of Al/diamond composites prepared by spark plasma sintering

Spark plasma sintering was used to fabricate Al/diamond composites.The effect of sintering temperature on the microstructure and thermal conductivity（TC） of the composites was investigated with the combination of experimental results and theoretical analysis.The composite sintered at 550℃shows high relative density and strong interfacial bonding,whereas the composites sintered at lower（520CC） and higher（580-600℃） temperatures indicate no interfacial bonding and poor interfacial bonding,respectively.High relative density and strong interfacial bonding can maximize the thermal conductivity of Al/diamond composites,and taking both effects of particle shape and inhomogeneous interfacial thermal conductance into consideration can give a fairly good prediction of composites＇ thermal conduction properties.

Effect of Thermal Treatment on the Grain Growth of Nanostructured YSZ Thermal Barrier Coating Prepared by Air Plasma Spraying

A nanostructured thermal barrier coating is prepared by air plasma spraying using the 8wt% Y_2O_3 partially stabilized zirconia nano-powder with an average grain size of 40 nm. The microstructure and phase composition of feedstock nano-powder and coating are investigated using SEM, TEM and XRD. It is found that the as-sprayed zirconia coating has an average grain size of 67 nm and mainly consistes of metastable tetragonal phase, together with some monoclinic phase and tetragonal phase. Thermal treatment results show that the grains of the nanostructured coating grow slightly below 900℃, whereas over 1000℃ the gains grow rapidly and monoclinic phase noticeably appeares.

Vitrification of MSWI Fly Ash by Thermal Plasma Melting and Fate of Heavy Metals

Municipal solid waste incinerator （MSWI） fly ash with high basicity （about 1.68） was vitrified in a thermal plasma melting furnace system. Through the thermal plasma treatment, the vitrified product （slag） with amorphous dark glassy structure was obtained, and the leachability of hazardous metals in slag was significantly reduced. Meanwhile, it was found that the cooling rate affects significantly the immobility of heavy metals in slag. The mass distribution of heavy metals （Zn, Cd, Cr, Pb, As, Hg） was investigated in residual products （slag, secondary residues and flue gas）, in order to analyze the behavior of heavy metals in thermal plasma atmosphere. Heavy metal species with low boiling points accounting for the major fraction of their input-mass were adsorbed in secondary residues by pollution abatement devices, while those with high boiling points tended to be encapsulated in slag.

Effect of processing parameters on the microstructure and thermal conductivity of diamond/Ag composites fabricated by spark plasma sintering

Diamond/metal composites with 50 vol.% diamond have been produced by spark plasma sintering（SPS） using pure Ag as a matrix and diamond particles as reinforcement.Three kinds of powder mixing processes were used to prepare the mixture of diamond/Ag powders：dry mixing without milling medium,wet mixing and magnetic blending.Subsequently,they were all consolidated by SPS at various processing parameters to produce bulk diamond/Ag composites.Then samples were heat treated in order to obtain a higher thermal conductivity.The effect of processing parameters on the morphologies of the mixed powders,the microstructure and the thermal conductivity of the composites were investigated by comparing the experimental data.It reveals that particles were easy to agglomerate and the distribution of mixed powders was inhomogeneous by dry mixing method,and wet mixing method is too complex.The most favorable mixing process is magnetic blending by which the powders can be homogenously mixed and the composites prepared by optimized SPS processing parameters can obtain the highest relative density and the best thermal conductivity among the composites prepared by different processes.The magnetic blending diamond/Ag composites even have a 23% increase in thermal conductivity compared with pure silver sintered by SPS.

Deformation Behavior of Nanostructured Ceramic Coatings Deposited by Thermal Plasma Spray

Al2O3-13 wt pet TiO2 coating deposited by direct current plasma spray consists of nanostructured region and micro-lamellae. Bend test shows that the ceramic coating can sustain some deformation without sudden failure. The deformation is achieved through the movement of nano-particles in the nanostructured region under tensile stress.

Synergetic effect between non-thermal plasma and photocatalytic oxidation on the degradation of gas-phase toluene: Role of ozone

In this study, a hybrid process using non‐thermal plasma (NTP) and photocatalytic oxidation (PCO) was adopted for the degradation of gas‐phase toluene using TiO2 as the photocatalyst. To discover the synergetic effect between NTP and PCO, the performances of both sole (O3, UV, NTP, and PCO) and combined (O3 + TiO2, O3 + UV, NTP + UV, O3 + PCO, and NTP + PCO) processes were investigated from different perspectives, such as the toluene removal efficiency, selectivity of COx, mineralization rate, ozone utilization, and the generation of by‐products. The toluene removal efficiency of the combined NTP + PCO process was 80.2%, which was much higher than that of a sole degradation process such as NTP (18.8%) and PCO (13.4%). The selectivity of CO2 and the ozone utilization efficiency also significantly improved. The amount of by‐products in the gas phase and the carbon‐ based intermediates adsorbed on the catalyst surface dramatically reduced. The improvement in the overall performances of the combined NTP + PCO process was mainly ascribed to the efficient utilization of ozone in the photocatalytic oxidation, and the ozone further acting as an electron acceptor and scavenger, generating more hydroxyl radicals and reducing the recombination of electron‐ hole pairs.

Boudouard reaction driven by thermal plasma for efficient CO2 conversion and energy storage

Conversion of CO2 into CO using plasma processing powered by renewable energy is a promising method to convert intermittent sustainable electricity into storable chemical energy.Despite extensive research efforts worldwide,there is currently no process that achieves economically viable values for both CO2 conversion fraction and energy recovery efficiency simultaneously.Here we demonstrate that a process that utilizes the Boudouard reaction,CO^2++C→2 CO,driven by a thermal plasma allows both 95%CO2 conversion to CO and energy recovery efficiency of 70%,values far higher than seen so far.By comparing the conversion process with and without CO2 excitation by a plasma and by using optical emission spectroscopy we show that the improved performance is due to a novel mode of operation where CO2 is pyrolyzed into an active mixture of CO,O and O2 by an arc discharge which is then introduced into a fixed bed to interact with carbon material.In this way,the free oxygen in the mixture combusts with carbon to form CO,and residual plasma excited CO2 is reduced by carbon.In the overall process,the endothermic Boudouard reaction is partially replaced by an exothermic reaction,and the excess electric energy to produce CO2 plasma is reused in the carbon bed.

CO_2 conversion by thermal plasma with carbon as reducing agent: high CO yield and energy efficiency

A key problem in CO_2 conversion by thermal plasma is suppressing the inverse reactions,CO?+?O?→?CO_2 and CO?+?0.5O_2?→?CO_2, to simultaneously obtain high CO yield and energy efficiency. This can be done by quickly quenching the decomposed gas or rapidly taking away free oxygen from decomposed gas. In this paper, experiments of CO_2 conversion by thermal plasma with carbon as a reducing agent are presented. Carbon quickly devoured free oxygen in thermal plasma decomposed gas, and not only is the inverse reaction completely suppressed, but the discharge energy to form oxygen atoms, oxygen molecular, and thermal energy is also reused.A CO_2 conversion rate of 67%–94% and the corresponding electric energy efficiency of about 70% are achieved, both are much higher than that seen so far by other plasma implementations.

Synthesis of Ni-CeO_2 catalyst for the partial oxidation of methane using RF thermal plasma

Ni‐CeO2 catalysts with a nickel content of 50 mol% were prepared using RF thermal plasma, and their catalytic activities for methane partial oxidation were characterized. For the synthesis of Ni‐CeO2 catalysts, a precursor containing Ni（～5‐μm diameter） and CeO2（～200‐nm diameter）powders were heated simultaneously using an RF plasma at a power level of ～52 kVA and a powder feeding rate of ～120 g/h. From the X‐ray diffraction data and transmission electron microscopy images, the precursor formed into high crystalline CeO2 supports with nanosized Ni particles（ 50‐nm diameter） on their surfaces. The catalytic performance was evaluated under atmospheric pressure at 500 °C and a CH4：O2 molar ratio of 2：1 with Ar diluent. Although the Ni content was high（～50 mol%）, the experimental results reveal a methane conversion rate of 70%, selectivities of CO and H2 greater than 90% and slight carbon coking during an on‐stream test at 550 °C for 24 h.However, at 750 °C, the on‐stream test revealed the formation of filament‐like carbons with an increased methane conversion rate over 90%.

Properties of negative thermal expansion β-eucryptite ceramics prepared by spark plasma sintering

β-eucryptite powders are prepared by the sol-gel method through using tetraethoxysilane lithium nitrate and aluminum isopropoxide as starting materials. β-eucryptite ceramics are prepared by spark plasma sintering. The effects of sintering temperature on the negative thermal expansion properties of the β-eucryptite are investigated by x-ray diffraction（XRD）, scanning electron microscopy, and thermal expansion test. The XRD results exhibit no change in the crystal structure of the sample prepared by different sintering processes. The negative thermal expansion properties increase with the increase of the sintering temperature. The coefficient of thermal expansion of β-eucryptite ceramics sintered at 1100℃ is calculated to be -4.93 × 10^（-6）℃^（-1）. Crystallization behaviors of the ceramics may play an important role in the increase of negative thermal expansion of β-eucryptite. High sintering temperature could improve the crystallization behaviors of the ceramics and reduce the residue glass phase, which can improve the negative thermal expansion properties of β-eucryptite ceramics.

Thermal behavior of B_4 Cparticles under plasma arc powder surfacing condition

The effect of plasma arc powder surfacing process on the amount of B4C particles in the coating and the thermal behavior of B4C particles in different surfacing stages has been investigated.The results showed that the feeding rate of B4C partiles is the most important factor affecting the amount of B4C particles in the surfacing coating among all the surfacing parameters,and the most part of B4C Particles in the coating is nto the remainders of original solid B4C particles,but the consolidation products of the unmelted liquid B4C globules in the pool.The results also showed that the B4C particles would not be melted in the plasma arc column, their melting process mainly takes place in the anode spot region on the surface of the pool when surfacing current is less than 200A.

Process optimization,microstructures and mechanical/thermal properties of Cu/Invar bi-metal matrix composites fabricated by spark plasma sintering

An orthogonal experiment scheme was designed to investigate the effects of the Cu content,compaction pressure,and sintering temperature on the microstructures and mechanical and thermal properties of(30−50)wt.%Cu/Invar bi-metal matrix composites fabricated via spark plasma sintering(SPS).The results indicated that as the Cu content increased from 30 to 50 wt.%,a continuous Cu network gradually appeared,and the density,thermal conductivity(TC)and coefficient of thermal expansion of the composites noticeably increased,but the tensile strength decreased.The increase in the sintering temperature promoted the Cu/Invar interface diffusion,leading to a reduction in the TC but an enhancement in the tensile strength of the composites.The compaction pressure comprehensively affected the thermal properties of the composites.The 50wt.%Cu/Invar composite sintered at 700℃ and 60 MPa had the highest TC(90.7 W/(m·K)),which was significantly higher than the TCs obtained for most of the previously reported Cu/Invar composites.

Understanding CO_2 decomposition by thermal plasma with supersonic expansion quench

CO2 pyrolysis by thermal plasma was investigated,and a high conversion rate of 33% and energy efficiency of 17% were obtained.The high performance benefited from a novel quenching method,which synergizes the converging nozzle and cooling tube.To understand the synergy effect,a computational fluid dynamics simulation was carried out.A quick quenching rate of 10~7Ks（-1） could be expected when the pyrolysis gas temperature decreased from more than 3000 to 1000 K.According to the simulation results,the quenching mechanism was discussed as follows： first,the compressible fluid was adiabatically expanded in the converging nozzle and accelerated to sonic speed,and parts of the heat energy converted to convective kinetic energy; second,the sonic fluid jet into the cooling tube formed a strong eddy,which greatly enhanced the heat transfer between the inverse-flowing fluid and cooling tube.These two mechanisms ensure a quick quenching to prevent the reverse reaction of CO2 pyrolysis gas when it flows out from the thermal plasma reactor.

Microstructure studies of air-plasma-spray-deposited CoNiCrAlY coatings before and after thermal cyclic loading for high-temperature application

In the present study, bond-coats for thermal barrier coatings were deposited via air plasma spraying（APS） techniques onto Inconel 800 and Hastelloy C-276 alloy substrates. Scanning electron microscopy（SEM）, transmission electron microscopy（TEM）, X-ray diffraction（XRD）, and atomic force microscopy（AFM） were used to investigate the phases and microstructure of the as-sprayed, APS-deposited Co Ni Cr Al Y bond-coatings. The aim of this work was to study the suitability of the bond-coat materials for high temperature applications. Confirmation of nanoscale grains of the γ/γ′-phase was obtained by TEM, high-resolution TEM, and AFM. We concluded that these changes result from the plastic deformation of the bond-coat during the deposition, resulting in Co Ni Cr Al Y bond-coatings with excellent thermal cyclic resistance suitable for use in high-temperature applications. Cyclic oxidative stability was observed to also depend on the underlying metallic alloy substrate.

Enthalpy Probe Technique for Thermal Plasma Diagnostics

The measuring principle and experimental results of the enthalpy probe technique for thermal plasma diagnostics are presented. Its calibration and errors are discussed. Typical results are presented for the system operation in an Ar/H2(5 % H2) plasma arc jet under a reactor chamber pressure of 101.3 kPa. The plasma temperature and velocity profiles are measured. The center temperature and velocity are 6600 K and 850 m/s for plasma power 9 kW at axial location of 17 mm.

Synthesis of Nano-Size AlN Powders by Carbothermal Reduction from Plasma-Assisted Ball Milling Precursor

Nano-size aluminum nitride （A1N） powders have been successfully synthesized with a high efficiency method through annealing from milling assisted by discharge plasma （p-milling） alumina （Al2O3） precursors. The characterization of the p-milling Al2O3 powders and the synthesized AlN are investigated. Compared to conventional ball milling （c-milling）, it can be found that the precursors by p-milling have a finer grain size with a higher specific surface area, which lead to a faster reaction efficiency and higher conversion to A1N at lower temperatures. The activation energy of p-milling Al2O3 is found to be 371.5 kJ/mol, a value that is much less than the reported value of the unmilled and the conventional milled Al2O3. Meanwhile, the synthesized AlN powders have unique features, such as an irregular lamp-like morphology with uniform particle distribution and fine average particle size. The results are attributed to the unique synergistic effect of p-milling, which is the effect of deformation, fracture, and cold welding of Al2O3 powders resulting from ball milling, that will be enhanced due to the introduction of discharge plasma.