Experimental Study on Wire Melting Control Ability of Twin-Body Plasma Arc

The twin-body plasma arc has the decoupling control ability of heat transfer and mass transfer,which is beneficial to shape and property control in wire arc additive manufacturing.In this paper,with the wire feeding speed as a characteristic quantity,the wire melting control ability of twin-body plasma arc was studied by adjusting the current separation ratio(under the condition of a constant total current),the wire current/main current and the position of the wire in the arc axial direction.The results showed that under the premise that the total current remains unchanged(100 A),as the current separation ratio increased,the middle and minimum melting amounts increased approximately synchronously under the effect of anode effect power,the first melting mass range remained constant;the maximum melting amount increased twice as fast as the middle melting amount under the effect of the wire feeding speed,and the second melting mass range was expanded.When the wire current increased,the anode effect power and the plasma arc power were both factors causing the increase in the wire melting amount;however,when the main current increased,the plasma arc power was the only factor causing the increase in the wire melting amount.The average wire melting increment caused by the anode effect power was approximately 2.7 times that caused by the plasma arc power.The minimum melting amount was not affected by the wire-torch distance under any current separation ratio tested.When the current separation ratio increased and reached a threshold,the middle melting amount remained constant with increasing wire-torch distance.When the current separation ratio continued to increase and reached the next threshold,the maximum melting amount remained constant with the increasing wire-torch distance.The effect of the wire-torch distance on the wire melting amount reduced with the increase in the current separation ratio.Through this study,the decoupling mechanism and ability of this innovative arc heat source is more clearly.

Atmospheric pressure pulsed modulated arc discharge plasma

Direct-current(DC)arc plasma has great application values in the field of the chemical industry,but it has the problem of low energy efficiency.Facing the requirement for improving the energy efficiency of the arc,this paper proposes a unique method of pulsed modulated arc(PMA).This method uses high-frequency pulses and reduces the arc current to improve the control of electron temperature.The electrical characteristics,optical characteristics and products are tested.The test results show that during the PMA process,all of the experimental results which include voltage,current and light will significantly increase.These results are analyzed from the perspective of functionality,repeatability and energy conversion.The analysis results show that although the PMA method does not show good parameter consistency,it has potential application prospects because it increases the energy conversion rate by 4.5%and 8%from the perspective of light and products,respectively.

Plasma diagnosis of tetrahedral amorphous carbon films by filtered cathodic vacuum arc deposition

Filtered cathodic vacuum arc(FCVA)deposition is regarded as an important technique for the synthesis of tetrahedral amorphous carbon(ta-C)films due to its high ionization rate,high deposition rate and effective filtration of macroparticles.Probing the plasma characteristics of arc discharge contributes to understanding the deposition mechanism of ta-C films on a microscopic level.This work focuses on the plasma diagnosis of an FCVA discharge using a Langmuir dualprobe system with a discrete Fourier transform smoothing method.During the ta-C film deposition,the arc current of graphite cathodes and deposition pressure vary from 30 to 90 A and from 0.3 to 0.9 Pa,respectively.The plasma density increases with arc current but decreases with pressure.The carbon plasma density generated by the arc discharge is around the order of10^(10)cm^(-3).The electron temperature varies in the range of 2-3.5 eV.As the number of cathodic arc sources and the current of the focused magnetic coil increase,the plasma density increases.The ratio of the intensity of the D-Raman peak and G-Raman peak(I_(D)/I_(G))of the ta-C films increases with increasing plasma density,resulting in a decrease in film hardness.It is indicated that the mechanical properties of ta-C films depend not only on the ion energy but also on the carbon plasma density.

Discussion on the Non-Equilibrium Phase of the Gliding Arc Plasma Driven by the Transverse Magnetic Field

a gliding arc driven by the transverse magnetic field was ignited between the electrodes with a complicated shape at atmospheric pressure and a non-equilibrium plasma was gencrated. Under our experimental conditions, a phenomenon was clearly observed where the arc power decreased with the increase in arc voltage. As the arc voltage was higher than 3.375 kV, the are power acquired from the power supply decreased, and the arc plasma began to switch to a non-equilibrium phase. The existence of the non-equilibrium arc plasma was very short, about 10 ms in one gliding arc discharge cycle.

Three-dimensional non-equilibrium modeling of a DC multi-cathode arc plasma torch

In this paper,a three-dimensional non-equilibrium steady arc model is used to investigate the temperature,velocity and electromagnetic field in multi-cathode arc torch,and the formation mechanism of a large-area,uniform and diffused arc plasma is analyzed.The numerical simulation results show that a large volume plasma region can be formed in the central region of the generator during discharge.During this process,the maximum electron temperature appears near the cathode and in the central convergence region,while the maximum heavy particle temperature only appears in the central convergence region.This phenomenon is consistent with the experimental arc images.Near the cathode tip,the arc column is in a contraction state.In the area slightly away from the cathode,the six arc columns begin to join together.In the plasma generator,there is a large-scale current distribution in all directions of X,Y and Z,forming a stable arc plasma with a wide range of diffusion.The calculated electron temperature distribution is in good agreement with the measured electron temperature.The results suggest that the largearea diffused arc plasma in the multi-cathode arc torch is the combined effect of current distribution,convection heat transfer and heat conduction.

Study on the formation of arc plasma on the resistive wall liquid metal current limiter

Due to its significant attributes,the liquid metal current limiter(LMCL)is considered a new strategy for limiting short-circuit current in the power grid.A resistive wall liquid metal current limiter(RWLMCL)is designed to advance the starting current-limiting time.Experiments are performed to investigate the dynamic behaviors of liquid metal,and the influence of different currents on the liquid metal self-shrinkage effect is compared and analyzed.Furthermore,the liquid metal self-shrinkage effect is mathematically modeled,and the reason for the formation of arc plasma is obtained by simulation.The laws of arc plasma formation and the current transfer in the cavity are revealed,and the motion mechanisms are explained by physical principles.The simulations are in accordance with the test data.It is demonstrated that the sudden change of the current density at both ends of the wall causes the liquid metal to shrink and depress under the electromagnetic force,and the current starts to transfer from the liquid metal path to the wall resistance path.The RWLMCL can effectively advance the starting current-limiting time.

Low-temperature chemistry in plasma-driven ammonia oxidative pyrolysis

Ammonia is gaining increasing attention as a green alternative fuel for achieving large-scale carbon emission reduction. Despite its potential technical prospects, the harsh ignition conditions and slow flame propagation speed of ammonia pose significant challenges to its application in engines. Non-equilibrium plasma has been identified as a promising method, but current research on plasma-enhanced ammonia combustion is limited and primarily focuses on ignition characteristics revealed by kinetic models. In this study, low-temperature and low-pressure chemistry in plasma-assisted ammonia oxidative pyrolysis is investigated by integrated studies of steady-state GC measurements and mathematical simulation. The detailed kinetic mechanism of NH_(3) decomposition in plasma-driven Ar/NH_(3) and Ar/NH_(3)/O_(2) mixtures has been developed. The numerical model has good agreements with the experimental measurements in NH_(3)/O_(2) consumption and N_(2)/H_(2) generation, which demonstrates the rationality of modelling. Based on the modelling results, species density profiles, path flux and sensitivity analysis for the key plasmaproduced species such as NH_(2), NH, H_(2), OH, H, O, O(^(1)D), O_(2)(a^(1)△_(g)), O_(2)(b^(1)∑_(g)^(+)), Ar^(*), H^(-), Ar^(+), NH_(3)^(+), O_(2)^(-) in the discharge and afterglow are analyzed in detail to illustrate the effectiveness of the active species on NH_(3) excitation and decomposition at low temperature and relatively higher E/N values. The results revealed that NH_(2), NH, H as well as H_(2) are primarily generated through the electron collision reactions e + NH_(3)→ e + NH_(2)+ H, e + NH_(3)→ e + NH + H_(2) and the excited-argon collision reaction Ar^(*) + NH_(3)+ H → Ar + NH_(2)+ 2H, which will then react with highly reactive oxidative species such as O_(2)^(*), O^(*), O, OH, and O_(2) to produce stable products of NOx and H_(2)O. NH_(3)→ NH is found a specific pathway for NH_(3) consumption with plasma assistance, which further highlights the enhanced kinetic effects.

Plasma nitrogen fixation system with dual-loop enhancement for improved energy efficiency and its efficacy for lettuce cultivation

Plasma nitrogen fixation(PNF)has been emerging as a promising technology for greenhouse gasfree and renewable energy-based agriculture.Yet,most PNF studies seldom address practical application-specific issues.In this work,we present the development of a compact and automatic PNF system for on-site agricultural applications.The system utilized a gliding-arc discharge as the plasma source and employed a dual-loop design to generate NO_(x)from air and water under atmospheric conditions.Experimental results showed that the system with a dualloop design performs well in terms of energy costs and production rates.Optimal operational parameters for the system were determined through experimentation,resulting in an energy cost of 13.9 MJ mol^(-1)and an energy efficiency of 16 g kWh^(-1)for NO_(3)^(-)production,respectively.Moreover,the concentration of exhausted NO_(x)was below the emission standards.Soilless lettuce cultivation experiments demonstrated that NO_(x)^(-)produced by the PNF system could serve as liquid nitrate nitrogen fertilizer.Overall,our work demonstrates the potential of the developed PNF system for on-site application in the production of green-leaf vegetables.

Effect of power supply parameters on discharge characteristics and sterilization efficiency of magnetically driven rotating gliding arc

Plasma sterilization is a new generation of high-tech sterilization method that is fast,safe,and pollution free.It is widely used in medical,food,and environmental protection fields.Home air sterilization is an emerging field of plasma application,which puts higher requirements on the miniaturization,operational stability,and operating cost of plasma device.In this study,a novel magnetically driven rotating gliding arc(MDRGA)discharge device was used to sterilize Lactobacillus fermentation.Compared with the traditional gas-driven gliding arc,this device has a simple structure and a more stable gliding arc.Simulation using COMSOL Multiphysics showed that adding permanent magnets can form a stable magnetic field,which is conducive to the formation of gliding arcs.Experiments on the discharge performance,ozone concentration,and sterilization effect were conducted using different power supply parameters.The results revealed that the MDRGA process can be divided into three stages:starting,gliding,and extinguishing.Appropriate voltage was the key factor for stable arc gliding,and both high and low voltages were not conducive to stable arc gliding and ozone production.In this experimental setup,the sterilization effect was the best at 6.6 kV.A high modulation duty ratio was beneficial for achieving stable arc gliding.However,when the duty ratio exceeded a certain value,the improvement in the sterilization effect was slow.Therefore,considering the sterilization effect and energy factors comprehensively,we chose 80%as the optimal modulation duty ratio for this experimental device.

Discharge and mass transfer characteristics of atmospheric pressure gas-solid two-phase gliding arc

In this work,a gas-solid two-phase gliding arc discharge(GS-GAD)reactor was built.Gliding arc was formed in the gap between the blade electrodes,and solid powder was deposited on the sieve plate positioned beneath the blade electrodes.A range of experimental parameters,including the inter-electrode spacing,gas flow rate,applied voltage,and the type of the powder,were systematically varied to elucidate the influence of solid powder matter on the dynamics of gliding arc discharge(GAD).The discharge images were captured by ICCD and digital camera to investigate the mass transfer characteristics of GS-GAD,and the electrical parameters,such as the effective values of voltage,current,and discharge power were record to reveal the discharge characteristics of GS-GAD.The results demonstrate that powder undergoes spontaneous movement towards the upper region of the gliding arc due to the influence of electric field force.Increasing the discharge voltage,decreasing relative dielectric constant of the powder and reducing the electrode-to-sieve-plate distance all contribute to a greater involvement of powder in the GAD process,subsequently resulting in an enhanced powder concentration within the GAD region.Additionally,powder located beneath the gliding arc experiences downward resistance caused by the opposing gas flow and arc.Excessive gas flow rate notably hampers the powder concentration within the discharge region,and the velocity of powder motion in the upper part of the GAD region is reduced.Under the condition of electrode-to-sieve-plate distance of 30 mm,gas flow rate of 1.5 L/min,and peak-to-peak voltage of 31 kV,the best combination of arc gliding and powder spark discharge phenomena can be achieved with the addition of Al_(2)O_(3) powder.

Effect of Ti-Si-Mg-Al wire on microstructure and mechanical properties of plasma arc in-situ welded joint of SiC_p/Al composites

The influence of Ti-Si-Mg-AI wire on microstructure and mechanical properties of SiCp/A1 metal matrix composite joints produced by plasma arc in-situ weld-alloying was investigated. Argon-nitrogen mixture was used as plasma gas and Ti-Si-Mg-A1 flux-cored wires as filled composites. Weldments were submitted to tensile test. Meanwhile, the macro morphology and microstructure of the joints were examined. The result shows that the formation ofneedie-like harmful phase A14C3 is effectively inhibited and the wettability of molten pool is improved by adding Ti-Si-Mg-A1 flux-cored wires. With 15Ti-5Si-5Mg-A1 flux-cored wire as filled composite, the maximum tensile strength of the welded joint is 267 MPa, which is up to 83% that of the matrix composites under annealed condition.

Effect of arc-ultrasound on microstructures and mechanical properties of plasma arc welded joints of SiC_p/Al MMCs

The effect of arc-ultrasound on microstructures and mechanical properties of SiCp/6061A1 MMCs joints produced by arc-ultrasound plasma arc ＂in-situ＂ alloy-welding with different excitation frequencies was investigated, in which argon-nitrogen mixture was used as plasma gas, Ti wire as filler and the arc-ultrasound was produced by modulating the plasma arc with high frequency. The results show that arc-ultrasound could refine the new reinforced composites such as TiC, TiN significantly, and improve their distribution greatly. And new phase A13Ti becomes finer and less. The test results of mechanical properties indicate that the maximum tensile strength of welded joints is gained when the excitation frequency is 50 kHz, and the maximum is 225 MPa, raising by about 7% comoared with conventional nlasma arc welding （PAW） （20q MPa）.

Welding of Ti-6Al-4V alloy using dynamically controlled plasma arc welding process

A novel dynamically controlled plasma arc welding process was introduced,which is able tominimize heat input into the workpiece materials while maintaining desired full penetration,and it was used to weld Ti-6Al-4V alloy sheets.The microstructures,facture surfaces and microhardness of the welded joints were characterized by using optical microscope,scanning electron microscope （SEM） and Vickers microhardness tester.Comparing with welds such as gas tungsten arc and conventional plasma arc processes,the experimental results revealed the improvements when using the present process including：1） reducing prior-beta （β） grain size and prohibiting formation of hard martensite phases in the fusion zone due to the decreased heat input;and 2） better toughness and higher hardness.

采用DC Arc Plasma JetCVD方法沉积微/纳米复合自支撑金刚石膜

在30kW级直流电弧等离子体喷射化学气相沉积(DC Arc P lasm a Jet CVD)设备上,采用Ar-H2-CH4混合气体,通过调节甲烷浓度以及控制其他沉积参数,在Mo衬底上沉积出微/纳米复合自支撑金刚石膜。实验表明,当微米金刚石膜层沉积结束后,在随后的沉积中,随着甲烷浓度的增加,金刚石膜表面的晶粒大小是逐渐减小的。当甲烷浓度达到20%以上时,金刚石膜生长面晶粒呈现菜花状的小晶团,膜体侧面已经没有了粗大的柱状晶,而是呈现出光滑的断口,对该层进行拉曼谱分析显示,位于1145 cm-1附近有一定强度的散射峰出现。这说明所沉积的晶粒全部变为纳米级尺寸。

Characterization of carbon encapsulated Fe-nanoparticles prepared by confined arc plasma

Carbon encapsulated Fe nanoparticles were successfully prepared via confined arc plasma method. The composition, morphology, microstructure, specific surface area and particle size of the product were characterized via X-ray diffraction, transmission electron microscopy, high resolution transmission electron microscopy, energy dispersive X-ray spectrometry and Brunauer-Emmett-Teller N2 adsorption. The experiment results show that the carbon encapsulated Fe nanoparticles have clear core-shell structure. The core of the particles is body centered cubic Fe, and the shell is disorder carbons. The particles are in spherical or ellipsoidal shapes. The particle size of the nanocapsules ranges from 15 to 40 nm, with the average value of about 30 nm. The particle diameter of the core is 18 nm, the thickness of the shells is 6-8 nm, and the specific surface area is 24 m2/g.

Hydrogen storage properties of Mg-TiO_2 composite powder prepared by arc plasma method

Mg-based Mg-TiO2 composite powder was prepared by arc plasma evaporation of the Mg＋5%TiO2 mixture followed by passivation in air. ICP, XRD and SEM techniques were used to characterize the composition, phase components and microstructure of the composite powder. The hydrogen sorption properties of the composite powder were investigated by DSC and PCT techniques. According to the data from PCT measurements, the hydrogenation enthalpy and entropy changes of the composite powder are calculated to be-71.5 kJ/mol and-130.1 J/（K·mol）, respectively. Besides, the hydrogenation activation energy is determined to be 77.2 kJ/ mol. The results indicate that TiO2 added into Mg by arc plasma method can act as a catalyst to improve the hydrogen sorption kinetic properties of Mg.

Numerical Study on Arc Plasma Behavior During Arc Commutation Process in Direct Current Circuit Breaker

This paper focuses on the numerical investigation of arc plasma behavior during arc commutation process in a medium-voltage direct current circuit breaker （DCCB） contact system. A three-dimensional magneto-hydrodynamic （MHD） model of air arc plasma in the contact system of a DCCB is developed, based on commercial software FLUENT. Coupled electromagnetic and gas dynamic interactions are considered as usual, and a thin layer of nonlinear electrical resistance elements is used to represent the voltage drop of plasma sheath and the formation of new arc root. The distributions of pressure, temperature, gas flow and current density of arc plasma in arc region are calculated. The simulation results indicate that the pressure distribution related to the contact system has a strong effect on the arc commutation process, arising from the change of electrical conductivity in the arc root region. In DCCB contact system, the pressure of arc root region will be concentrated and higher if the space above the moving contact is enclosed, which is not good for arc root commutation. However, when the region is opened, the pressure distribution would be lower and more evenly, which is favorable for the arc root commutation.

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 velocity 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.

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.

Effects of Y_2O_3 on the microstructure and wear resistance of cobalt-based alloy coatings deposited by plasma transferred arc process

Cobalt-based alloys with different Y2O3 contents were deposited on Q235A-carbon steel using plasma transferred arc （PTA） welding machine. The effect of Y2O3 on the microstructure and wear resistance properties of the cobait-based alloys were investigated using an optical microscope, a scanning electron microscope （SEM）, X-ray diffraction （XRD）, and transmission electron microscopy （TEM）. It was found that a cobalt-based solid solution with a face-centered cubic crystal structure was presented accompanied by the secondary phase M7C3 with a hexagonal crystal structure in the Y2O3-free cobalt-based alloy coating. Several stacking faults exist in the cobalt-based solid solution. The addition of Y2O3 leads to the existence of the Y2O3 phase in the Y2O3-modified coatings. Though stacking fault exists in the Y2O3-modified coatings, its density increases. The addition of Y2O3 can refine the microstructure and can increase the wear resistance properties when its contents are less than or equal to 0.8 wt.%. However, further increase of its contents will lead to the agglomeration of undissolved Y2O3 particles at the γ-Co grain boundary, and will lead to a coarse microstructure and lower wear resistance properties.