On the evolution and formation of discharge morphology in pulsed dielectric barrier discharge

The discharge morphology of pulsed dielectric barrier discharge(PDBD) plays important roles in its applications. Here, we systematically investigated the effects of the voltage amplitude,discharge gap, and O_(2)content on the PDBD morphology, and revealed the possible underlying mechanism of the U-shaped formation. First, the morphological evolution under different conditions was recorded. A unique U-shaped region appears in the middle edge region when the gap is larger than 2 mm, while the entire discharge region remains columnar under a 2 mm gap in He PDBD. The width of the discharge and the U-shaped region increase with the increase in voltage, and decrease with the increase of the gap and O_(2)content. To explain this phenomenon,a two-dimensional symmetric model was developed to simulate the spatiotemporal evolution of different species and calculate the electric thrust. The discharge morphology evolution directly corresponds to the excited-state atomic reduction process. The electric thrust on the charged particles mainly determines the reaction region and strongly influences the U-shaped formation.When the gap is less than 2 mm, the electric thrust is homogeneous throughout the entire region,resulting in a columnar shape. However, when the gap is larger than 2 mm or O_(2)is added, the electric thrust in the edge region becomes greater than that in the middle, leading to the U-shaped formation. Furthermore, in He PDBD, the charged particles generating electric thrust are mainly electrons and helium ions, while in He/O_(2)PDBD those that generate electric thrust at the outer edge of the electrode surface are mainly various oxygen-containing ions.

Experimental and numerical investigation on the uniformity of nanosecond pulsed dielectric barrier discharge influenced by pulse parameters

Nanosecond(ns)pulsed dielectric barrier discharge(DBD)is considered as a promising method to produce controllable large-volume and high activity low-temperature plasma at atmospheric pressure,which makes it suitable for wide applications.In this work,the ns pulse power supply is used to excite Ar DBD and the influences of the pulse parameters(voltage amplitude,pulse width,pulse rise and fall times)on the DBD uniformity are investigated.The gas gap voltage(Ug)and conduct current(Ig)are separated from the measured voltage and current waveforms to analyze the influence of electrical parameters.The spectral line intensity ratio of two Ar excited species is used as an indicator of the electron temperature(Te).The time resolved discharge processes are recorded by an intensified charge-coupled device camera and a one-dimensional fluid model is employed to simulate the spatial and temporal distributions of electrons,ions,metastable argon atoms and Te.Combining the experimental and numerical results,the mechanism of the pulse parameters influencing on the discharge uniformity is discussed.It is shown that the space electric field intensity and the space particles'densities are mainly responsible for the variation of discharge uniformity.With the increase of voltage and pulse width,the electric field intensity and the density of space particles increased,which results in the discharge mode transition from non-uniform to uniform,and then non-uniform.Furthermore,the extension of pulse rise and fall times leads to the discharge transition from uniform to nonuniform.The results are helpful to reveal the mechanism of ns pulsed DBD mode transition and to realize controllable and uniform plasma sources at atmospheric pressure.

Optimization of micro milling electrical discharge machining of Inconel 718 by Grey-Taguchi method

The optimization of micro milling electrical discharge machining（EDM） process parameters of Inconel 718 alloy to achieve multiple performance characteristics such as low electrode wear,high material removal rate and low working gap was investigated by the Grey-Taguchi method.The influences of peak current,pulse on-time,pulse off-time and spark gap on electrode wear（EW）,material removal rate（MRR） and working gap（WG） in the micro milling electrical discharge machining of Inconel 718 were analyzed.The experimental results show that the electrode wear decreases from 5.6×10-9 to 5.2×10-9 mm3/min,the material removal rate increases from 0.47×10-8 to 1.68×10-8 mm3/min,and the working gap decreases from 1.27 to 1.19 μm under optimal micro milling electrical discharge machining process parameters.Hence,it is clearly shown that multiple performance characteristics can be improved by using the Grey-Taguchi method.

Review on reactive species in water treatment using electrical discharge plasma:formation, measurement, mechanisms and mass transfer

In the electrical discharge plasma process, various chemical and physical processes can participate in the removal of contaminants. In this paper, the chemical and physical processes that occur as a result of the electrical discharge plasma are reviewed, and their possible roles in the degradation of contaminants are discussed. Measurement methods for the quantification of important reactive species and their advantages and shortcomings are presented. Approaches on how to enhance the diffusion of the reactive species in solution are examined. In addition, the formation of typical reactive species in different electrical discharge plasma is compared.

NOx Reduction and Desorption Studies Under Electric Discharge Plasma Using a Simulated Gas Mixture:A Case Study on the Effect of Corona Electrodes

In this study, reduction and desorption of oxides of nitrogen （NOx） were conducted using an electrical discharge plasma technique. The study was carried out using a simulated gas mixture to explore the possibility of re-generation of used adsorbents by a nonthermal plasma desorption technique. Three different types of corona electrodes, namely, pipe, helical wire, and straight wire, were used for analyzing their effectiveness in NOx reduction/desorption. The pipe- type corona electrode exhibited a nitric oxide （NO） conversion of 50%, which is 1.5 times that of the straight-wire-type electrode at an energy density of 175 J/L. The helical-wire-type corona electrode exhibited a NOx desorption efficiency almost 4 times that of the pipe-type electrode, indicating the possibility that corona-generated species play a crucial role in desorption.

Surface Modification Process by Electrical Discharge Machining with Ti Powder Green Compact Electrode

This paper describes a new method of surface modification by Electrical Discharge Machining (EDM). By using ordinary EDM machine tool and kerosene fluid, a hard ceramic layer can be created on the workpiece surface with Ti or other compressed powder electrode in a certain condition. This new revolutionary method is called Electrical Discharge Coating (EDC). The process of EDC begins with electrode wear during EDM,then a kind of hard carbide is created through the thermal and chemical reaction between the worn electrode material and the carbon particle decomposed from kerosene fluid under high temperature. The carbide is piled up on a workpiece quickly and becomes a hard layer of ceramic about 20 μm in several minutes. This paper studies the principle and process of EDC systemically by using Ti powder green compact electrode. In order to obtain a layer of compact ceramic film, it is very important to select proper electric pulse parameters, such as pulse width, pulse interval, peak current. Meantime, the electrode materials and its forming mode will effect the machining surface quality greatly. This paper presents a series of experiment results to study the EDC process by adopt different technology parameters. Experiments and analyses show that a compact TiC ceramic layer can be created on the surface of metal workpiece. The hardness of ceramic layer is more 3 times higher than the base body, and the hardness changes gradiently from surface to base body. The method will have a great future because many materials can be easily added to the electrode and then be coated on the workpiece surface. Gearing the parameters ceramic can be created with different thickness. The switch between deposition and removal process is carried out easily by changing the polarity, thus the gear to the thickness and shape of the composite ceramic layer is carried out easily. This kind of composite ceramic layer will be used to deal with the surface of the cutting tools or molds possibly, in order to lengthen their life. It also can be found wide application in the fields of surface repairing and strengthening of the ship or aircraft.

Statistical Description of Debris Particle Size Distribution in Electrical Discharge Machining

Gap debris as discharge product is closely related to machining process in electrical discharge machining（EDM）. A lot of recent researches have focused on the relationship among debris size, surfaces texture, remove rate, and machining stability. The study on statistical distribution of debris size contributes to the research, but it is still superficial currently. In order to obtain the distribution law of the debris particle size, laser particle size analyzer（LPSA） combined with scanning electron microscope（SEM） is used to analyze the EDM debris size. Firstly, the heating dried method is applied to obtain the debris particles. Secondly, the measuring range of LPSA is determined as 0.5–100 μm by SEM observation, and the frequency distribution histogram and the cumulative frequency distribution scattergram of debris size are obtained by using LPSA. Thirdly, according to the distribution characteristic of the frequency distribution histogram, the statistical distribution functions of lognormal, exponentially modified Gaussian（EMG）, Gamma and Weibull are chosen to achieve curve fitting of the histogram. At last, the distribute law of the debris size is obtained by fitting results. Experiments with different discharge parameters are carried out on an EDM machine designed by the authors themselves, and the machining conditions are tool electrode of red-copper material, workpiece of ANSI 1045 material and working fluid of de-ionized water. The experimental results indicate that the debris sizes of all experiment sample truly obey the Weibull distribution. The obtained distribution law is significantly important for all the models established based on the debris particle size.

Degradation of Synthetic Dyeing Wastewater by Underwater Electrical Discharge Processes

Electrical discharge treatments of synthetic dyeing wastewater were carried out with two different systems： underwater pulsed electrical discharge （UPED） and underwater dielectric barrier discharge （UDBD）. Reactive Blue 4 （RB4） and Acid Red 4 （AR4） were used as model contaminants for the synthetic wastewater. The performance of the aforementioned systems was compared with respect to the chromaticity removal and the energy requirement. The results showed that the present electrical discharge systems were very effective for degradation of the dyes. The dependences of the dye degradation rate on treatment time, initial dye concentration, electrical energy, and the type of working gas including air, 02, and N2 were examined. The change in the initial dye concentration did not largely affect the degradation of either RB4 or AR4. The energy delivered to the UPED system was only partially utilized for generating reactive species capable of degrading the dyes, leading to higher energy requirement than the UDBD system. Among the working gases, the best performance was observed with O2. As the degradation proceeded, the concentration of total dissolved solids and the solution conductivity kept increasing while pH showed a decreasing trend, revealing that the dyes were effectively mineralized.

Micro Electrical Discharge Machining Deposition in Air for Fabrication of Micro Spiral Structures

Micro electrical discharge machining（EDM） deposition process is a new micro machining method for fabrication of metal micro structures. In this process, the high level of tool electrode wear is used to achieve the metal material deposition. Up to now, the studies of micro EDM deposition process focused mainly on the researches of deposition process, namely the effects of discharge parameters in deposition process on the deposition rate or deposition quality. The research of the formation of micro structures with different discharge energy density still lacks. With proper conditions and only by the z-axis feeding in vertical direction, a novel shape of micro spiral structure can be deposited, with 0.11 mm in wire diameter, 0.20 mm in outside diameter, and 3.78 mm in height. Then some new deposition strategies including angular deposition and against the gravity deposition were also successful. In order to find the forming mechanism of the spiral structures, the numerical simulation of the transient temperature distribution on the discharge point was conducted by using the finite-element method（FEM）. The results show that there are two major factors lead to the forming of the spiral structures. One is the different material removal form of tool electrode according with the discharge energy density, the other is the influenced degree of the movement of the removed material particles in the discharge gap. The more the energy density in single discharge is, the smaller the mass of the removed material particles is, and the easier the movements of which will be changed to form an order tendency. The fine texture characteristics of the deposited micro spiral structures were analyzed by the energy spectrum analysis and the metallographic analysis. It shows that the components of the deposited material are almost the same as those of the tool electrode. Moreover the deposited material has the brass metallic luster in the longitudinal profile and has compact bonding with the base material. This research is useful to understand the micro-process of micro EDM deposition better and helpful to increase the controllability of the new EDM method for fabrication of micro structures.

Friction and wear behaviors of TiCN coating based on electrical discharge coating

Titanium carbonitride (TiCN) coating was prepared on 45# carbon steel by electrical discharge coating (EDC), and the compositions, morphology and microstructure of the coating were studied. In addition, its friction and wear behaviors relative to the physical vapor deposition (PVD) TiN coating were investigated. The results show that the TiCN coating features a thickness of 15μm with a primary phase of TiC 0.3 N 0.7 . The wear rates of the two coatings have no clear distinction at low applied loads. However, severe abrasive wear appears in the PVD TiN coating when the applied load exceeds 30 N, while the TiCN coating features better wear resistance. The abrasive wear with coating peelings is found to be the predominant wear mechanism at high applied loads.

Electric characteristic and cavitation bubble dynamics using underwater pulsed discharge

Underwater pulsed discharge is widely applied in medicine, machining, and material modification.The induced cavitation bubble and subsequent cavitation collapse are considered the major motivations behind these applications. This paper presents an underwater pulsed discharge system.The experimental setup is established to induce and investigate the cavitation bubble assisted with a high-speed camera. Three aspects, including the characteristic of the discharge with different applied voltages and conductivities, the evolution of the cavitation bubble profile, and the energy efficiency of cavitation bubble inducing, are investigated, respectively. Especially, the mechanism of pre-discharge time delay in the low field intensity case is explained using the Joule heat effect.The results show the validity of the underwater pulsed discharger and experimental setup. The present underwater pulsed discharger is proved to be a simple, portable, and easy-to-implement device for the investigation of cavitation bubble dynamics.

Improving energy utilization efficiency of electrical discharge milling in titanium alloys machining

Electrical discharge milling(ED-milling) can be a good choice for titanium alloys machining and it was proven that its machining efficiency can be improved to compete with mechanical cutting. In order to improve energy utilization efficiency of ED-milling process, unstable arc discharge and stable arc discharge combined with normal discharge were implemented for material removal by adjusting servo control strategy. The influence of electrode rotating speed and dielectric flushing pressure on machining performance was investigated by experiments. It was found that the rotating of electrode could move the position of discharge plasma channel, and high pressure flushing could wash melted debris out the discharge gap effectively. Both electrode rotating motion and high pressure flushing are contributed to the improvement of machining efficiency.

Experimental Research on Effects of Process Parameters on Servo Scanning 3D Micro Electrical Discharge Machining

Servo scanning 3D micro electrical discharge machining (3D SSMEDM) is a novel and effective method in fabricating complex 3D micro structures with high aspect ratio on conducting materials. In 3D SSMEDM process, the axial wear of tool electrode can be compensated automatically by servo-keeping discharge gap, instead of the traditional methods that depend on experiential models or intermittent compensation. However, the effects of process parameters on 3D SSMEDM have not been reported up until now. In this study, the emphasis is laid on the effects of pulse duration, peak current, machining polarity, track style, track overlap, and scanning velocity on the 3D SSMEDM performances of machining efficiency, processing status, and surface accuracy. A series of experiments were carried out by machining a micro-rectangle cavity (900 μm×600 μm) on doped silicon. The experimental results were obtained as follows. Peak current plays a main role in machining efficiency and surface accuracy. Pulse duration affects obviously the stability of discharge state. The material removal rate of cathode processing is about 3/5 of that of anode processing. Compared with direction-parallel path, contour-parallel path is better in counteracting the lateral wear of tool electrode end. Scanning velocity should be selected moderately to avoid electric arc and short. Track overlap should be slightly less than the radius of tool electrode. In addition, a typical 3D micro structure of eye shape was machined based on the optimized process parameters. These results are beneficial to improve machining stability, accuracy, and efficiency in 3D SSMEDM.

Electric ignition energy evaluation and the energy distribution structure of energy released in electrostatic discharge process

Ignition energy is one of tbe important parameters of flammable materials, and evaluating ignition energy precisely is essential to the safety of process industry and combustion science and technology. By using electric spark discharge test system, a series of electric spark discharge experiments were conducted with the capacitor-stored energy in the range of 10 J, 100 J, and 1000 J, respectively. The evaluation method for energy consumed by electric spark, wire, and switch during capacitor discharge process has been studied respectively. The resistance of wire, switch, and plasma between electrodes has been evaluated by different methods and an optimized evaluation method has been obtained. The electric energy consumed by wire, electric switch, and electric spark-induced plasma between electrodes were obtained and the energy structure of capacitor-released energy was analyzed. The dynamic process and the characteristic parameters （the maximum power, duration of discharge process） of electric spark discharge process have been analyzed. Experimental results showed that, electric spark-consumed energy only accounts for 8%-14% of the capacitor-released energy. With the increase of capacitor-released energy, the duration of discharge process becomes longer, and the energy of plasma accounts for more in the capacitor-released energy. The power of electric spark varies with time as a damped sinusoids function and the period and the maximum value increase with the capacitor-released energy.

Conversion of NO with a catalytic packedbed dielectric barrier discharge reactor

This paper discusses the conversion of nitric oxide（NO） with a low-temperature plasma induced by a catalytic packed-bed dielectric barrier discharge（DBD） reactor. Alumina oxide（Al2O3）,glass（SiO2） and zirconium oxide（ZrO2）, three different spherical packed materials of the same size, were each present in the DBD reactor. The NO conversion under varying input voltage and specific energy density, and the effects of catalysts（titanium dioxide（TiO2） and manganese oxide（Mn Ox） coated on Al2O3） on NO conversion were investigated. The experimental results showed that NO conversion was greatly enhanced in the presence of packed materials in the reactor, and the catalytic packed bed of Mn Ox/Al2O3 showed better performance than that of TiO2/Al2O3. The surface and crystal structures of the materials and catalysts were characterized through scanning electron microscopy analysis. The final products were clearly observed by a Fourier transform infrared spectrometer and provided a better understanding of NO conversion.

Study of Pulsed Plasma in a Crossed Flow Dielectric Barrier Discharge Reactor for Improvement of NO_x Removal in Raw Diesel Engine Exhaust

Improved performance of plasma in raw engine exhaust treatment is reported. A new type of reactor referred to as of cross-flow dielectric barrier discharge （DBD） was used, in which the gas flow is perpendicular to the corona electrode. In raw exhaust environment, the cross-flow （radial-flow） reactor exhibits a superior performance with regard to NOx removal when compared to that with axial flow of gas. Experiments were conducted at different flow rates ranging from 2 L/min to 25 L/min. The plasma assisted barrier discharge reactor has shown encouraging results in NOx removal at high flow rates.

CUTTING REGULARITY AND DISCHARGE CHARACTERISTICS BY USING COMPOSITE COOLING LIQUID IN WIRE CUT ELECTRICAL DISCHARGE MACHINE WITH HIGH WIRE TRAVELING SPEED

The analysis of cutting regularity is provided through using and comparing two typical cooling liquids. It is proved that cutting regularity is greatly affected by cooling liquid＇s washing ability. Discharge characteristics and theoretic analysis between two electrodes are also discussed based on discharge waveform. By using composite cooling liquid which has strong washing ability, the efficiency in the first stable cutting phase has reached more than 200 mm^2/min, and the roughness of the surface has reached Ra〈0.8 μm after the fourth cutting with more than 50 mm^2/min average cutting efficiency. It is pointed out that cutting situation of the wire cut electrical discharge machine with high wire traveling speed （HSWEDM） is better than the wire cut electrical discharge machine with low wire traveling speed （LSWEDM） in the condition of improving the cooling liquid washing ability. The machining indices of HSWEDM will be increased remarkably by using the composite cooling liquid.

Plasma-assisted methane conversion in an atmospheric pressure dielectric barrier discharge reactor

In this paper, a cylindrical dielectric barrier discharge （DBD） reactor has been developed for the conversion of methane into hydrogen and other valuable chemicals. The effects of a wide range of processing parameters including discharge power, residence time and frequency on the performance of plasma methane conversion reaction have been investigated. The results show that the CH4 DBD could be characterized as a typical filamentary discharge with a microdis-charge zone in each half-cycle of the applied voltage. The conversion of CH4 reaches a maximum of 25.2% at a feed flow rate of 50 mL-min-1, a discharge power of 45 W and an excitation frequency of 20 kHz. It is found that the residence time of methane in the discharge zone has the most significant effect on both methane conversion and hydrogen yield, which are significantly higher at higher residence time.

Machining performance on hybrid process of abrasive jet machining and electrical discharge machining

To develop a hybrid process of abrasive jet machining (AJM) and electrical discharge machining (EDM),the effects of the hybrid process parameters on machining performance were comprehensively investigated to confirm the benefits of this hybrid process.The appropriate abrasives delivered by high speed gas media were incorporated with an EDM in gas system to construct the hybrid process of AJM and EDM,and then the high speed abrasives could impinge on the machined surface to remove the recast layer caused by EDM process to increase the efficiency of material removal and reduce the surface roughness.In this study,the benefits of the hybrid process were determined as the machining performance of hybrid process was compared with that of the EDM in gas system.The main process parameters were varied to explore their effects on material removal rate,surface roughness and surface integrities.The experimental results show that the hybrid process of AJM and EDM can enhance the machining efficiency and improve the surface quality.Consequently,the developed hybrid process can fit the requirements of modern manufacturing applications.

MICRO ELECTRICAL DISCHARGE MACHINING DEPOSITION IN AIR

A new deposition method is described using micro electrical discharge machining （EDM） to deposit tool electrode material on workpiece in air. The basic principles of micro electrical discharge deposition （EDD） are analyzed and the realized conditions are predicted. With an ordinary EDM shaping machine, brass as the electrode, high-speed steel as the workpiece, a lot of experiments are carried out on micro EDD systematically and thoroughly. The effects of major processing parameters, such as the discharge current, discharge duration, pulse interval and working medium, are obtained, As a result, a micro cylinder with 0.19 mm in diameter and 7.35 mm in height is deposited. By exchanging the polarities of the electrode and workpiece the micro cylinder can be removed selectively. So the reversible machining of deposition and removal is achieved, which breaks through the constraint of traditional EDM. Measurements show that the deposited material is compact and close to workpiece base, whose components depend on the tool electrode, material.