Modelling Study on the Plasma Flow and Heat Transfer in a Laminar Arc Plasma Torch Operating at Atmospheric and Reduced Pressure

A modelling study is performed to investigate the characteristics of both plasma flow and heat transfer of a laminar non-transferred arc argon plasma torch operated at atmospheric and reduced pressure. It is found that the calculated flow fields and temperature distributions are quite similar for both cases at a chamber pressure of 1.0 atm and 0.1 atm. A fully developed flow regime could be achieved in the arc constrictor-tube between the cathode and the anode of the plasma torch at 1.0 atm for all the flow rates covered in this study. However the flow field could not reach the fully developed regime at 0.1 atm with a higher flow rate. The arc-root is always attached to the torch anode surface near the upstream end of the anode, i.e. the abruptly expanded part of the torch channel, which is in consistence with experimental observation. The surrounding gas would be entrained from the torch exit into the torch interior due to a comparatively large inner diameter of the anode channel compared to that of the arc constrictor-tube.

Modelling Study to Compare the Flow and Heat Transfer Characteristics of Low-Power Hydrogen,Nitrogen and Argon Arc-Heated Thrusters

A modelling study is performed to compare the plasma flow and heat transfer characteristics of low-power arc-heated thrusters （arcjets） for three different propellants： hydrogen, nitrogen and argon. The all-speed SIMPLE algorithm is employed to solve the governing equations, which take into account the effects of compressibility, Lorentz force and Joule heating, as well as the temperature- and pressure-dependence of the gas properties. The temperature, velocity and Mach number distributions calculated within the thruster nozzle obtained with different propellant gases are compared for the same thruster structure, dimensions, inlet-gas stagnant pressure and arc currents. The temperature distributions in the solid region of the anode-nozzle wall are also given. It is found that the flow and energy conversion processes in the thruster nozzle show many similar features for all three propellants. For example, the propellant is heated mainly in the near-cathode and constrictor region, with the highest plasma temperature appearing near the cathode tip; the flow transition from the subsonic to supersonic regime occurs within the constrictor region; the highest axial velocity appears inside the nozzle; and most of the input propellant flows towards the thruster exit through the cooler gas region near the anode-nozzle wall. However, since the properties of hydrogen, nitrogen and argon, especially their molecular weights, specific enthMpies and thermal conductivities, are different, there are appreciable differences in arcjet performance. For example, compared to the other two propellants, the hydrogen arcjet thruster shows a higher plasma temperature in the arc region, and higher axial velocity but lower temperature at the thruster exit. Correspondingly, the hydrogen arcjet thruster has the highest specific impulse and arc voltage for the same inlet stagnant pressure and arc current. The predictions of the modelling are compared favourably with available experimental results.

Characterization of Low Pressure RF Plasma Heating

Compacts of a-Al2O3 and Mo powder were heated in radio-frequency (RF) induced low pressure N2, H2,Ar, and their mixture plasma. An optical pyrometer, a radiation pyrometer, and a system called Accufiber Model310 were used to measure the temperature of compacts heated in the plasma. The results indicate that there are different heat transfer mechanisms from plasma to specimens of different physical properties. The Ar plasma showed thehighest heating ability among N2, H2, and Ar plasma for Al2O3 specimens, whereas the H2 plasma could heat Mospecimens to a higher temperature than the Ar plasma did, even under the same generating conditions.

Numerical analysis on solidification process and heat transfer of FGH95 superalloy droplets during PREP

In order to understand the relation between microstructure of superalloypowders and its solidification progress, the processing parameters are optimized during plasmarotating electrode processing (PREP). It was predicted from the results that the droplet velocities,droplet temperature, and fractional solidification with flight time about FGH95 superalloy droplethave been carried out based on Newtonian heat transfer formulation coupled with the classicalheterogeneous nucleation and the specific solidification process. It has been found that the dropletdynamic and thermal behavior is strongly affected by the distribution of droplet diameters, theproportion of cooling atmosphere, but is relatively unaffected by the droplet superheat.

Nonequilibrium modeling study on plasma flow features in a low-power nitrogen/hydrogen arcjet thruster

Gasdynamic flow features in an electrothermal arcjet thruster with a mixture of 1：2 nitrogen/hydrogen as the working gas have been studied by a two-temperature numerical simulation.Seven species and 17 kinetic processes are included in the chemical kinetic model used to represent dissociation, ionization, and the corresponding recombination reactions in this nitrogen/hydrogen mixture system. Based on the gas flow characteristics inside the arcjet nozzle,a new method is introduced to define the edge of the cold boundary layer, which is more convenient to analyze the evolution and development of plasma flow in an arcjet thruster. The results show that the arcjet thruster performance is determined largely by the exchange of energy and momentum between the low-density, high-temperature arc region and the high-density, coolflow region near the nozzle wall. A significant thermal nonequilibrium is found in the cold boundary layer in the expansion portion of the nozzle. The important chemical kinetic processes determining the distribution of hydrogen and nitrogen species in different flow regions are presented. It has been shown that the reaction rate of hydrogen species ionization impacted by electrons is much higher than that of nitrogen species ionization in the center of the constrictor of the arcjet thruster. This indicates that hydrogen species is very important in the conversion of applied electric energy into thermal energy in the constrictor region of the arcjet thruster.

Application of In-Flight Melting Technology by RF Induction Thermal Plasmas to Glass Production

An innovative in-flight glass melting technology with induced thermal plasmas was developed for the purpose of energy conservation and environmental protection. Two-dimensional modeling was used to simulate the thermofluid fields in the plasma torch. The in-flight melting behavior of glass raw material was investigated by various analysis methods. Results showed that the plasma temperature was up to 10000 K with a maximum velocity over 30 m/s, which made it possible to melt the granulated glass raw material within milliseconds. The carbonates in the raw material decomposed completely and the compounds in the raw material attainted 100% vitrification during the in-flight time from the nozzle exit to substrate. The particle melting process is similar to the unreacted-core shrinking model.

Numerical Modeling of the High-Intensity Transferred Arc with a Water-Cooled Constrictor Tube

Stable and axi-symmetrical DC high-intensity transferred arcs with a coaxial water-cooled constrictor tube have been used to study the arc characteristics for many years. All the previous modeling studies concerning the high-intensity transferred arcs were restricted to the near-anode region. Modeling results are presented in this paper concerning the characteristics of the whole high-intensity transferred arc, referring to a recent experiment. It is shown that the computed flow and temperature fields for different flow rates of the working gas are overall similar, but a fully developed flow regime can only be achieved in the water-cooled constrictor tube at low working-gas flow rates. The predicted radial profiles of plasma temperature at the cross section near the constrictor-tube exit compare favorably with available experimental data, but corresponding comparison about the plasma axial-velocity profiles shows appreciable difference, revealing that there may exist considerable errors in the plasma velocity measurements using a sweeping Pitot tube.

Atmospheric Pressure Cold Argon/Oxygen Plasma Jet Assisted by Preionization of Syringe Needle Electrode

An atmospheric pressure nonequilibrium argon/oxygen plasma jet assisted by the preionization of syringe needle electrode discharge is reported. With the syringe needle plasma as its pre-ionization source, the hybrid barrier-jet was shown to generate uniform discharge with a lower breakdown voltage and a relatively low gas temperature varying from 390 K to 440 K, even when the vol.% oxygen in argon was up to 6%. Utilizing the actinometry method, the concentration of atomic oxygen was estimated to be about in an orders of magnitude of 10^17 cm^-3. The argon/oxygen plasma jet was then employed to clean out heat transfer oil, with a maximum cleaning rate of 0.1 mm/s achieved.

Analysis of the 3-D fluid velocity and temperature profile in keyhole plasma arc welding

Modeling and simulation of fluid flow and heat transfer in keyhole plasma arc welding is of great significance for optimizing the process parameters. In this study, a three-dimensional transient model is established to analyze numerically the heat transfer and fluid flow phenomena in keyhole plasma arc welding. VOF （volume of fluid） method is used to track the boundary of the keyhole. The dynamic developments of keyhole geometry, the fluid velocity field and temperature profiles are numerically simulated. And the changing Of the fluid velocity and pressure distribution on the keyhole wall in the forming process of the keyhole are analyzed.

Numerical and Experimental Investigation on the In-Flight Melting Behaviour of Granulated Powders in Induction Thermal Plasmas

An innovative in-flight glass melting technology with thermal plasmas was developed for the purpose of energy conservation and environment protection. In this study, modelling and experiments of argon-oxygen induction thermal plasmas were conducted to investigate the melting behaviour of granulated soda-lime glass powders injected into the plasma. A two-dimensional local thermodynamic equilibrium （LTE） model was performed to simulate the heat and momentum transfer between plasma and particle. Results showed that the particle temperature was strongly affected by the flow rate of carrier gas and the particle size of raw material. A higher flow rate of carrier gas led to lower particle temperature and less energy transferred to particles which resulted in lower vitrification. The incomplete melting of large particles was attributed to the lower central temperature of the particle caused by a larger heat capacity. The numerical analysis explained well the experimental results, which can provide valuable practical guidelines for the process control in the melting process for the glass industry.

Effect of Injection Position on In-Flight Melting Behavior of Granular Alkali-Free Glass Raw Material in 12-Phase AC Arc Plasma

An innovative in-flight glass melting technology with a multi-phase AC arc plasma was developed to save energy and reduce emissions for the glass industry. The effect of the injection position on the in-flight melting behavior of granulated powders was investigated. Results show that the injection position has a strong effect on the melting behavior of alkali-free glass raw material. With the increase in injection distance, the vitrification, decomposition, and particle shrinkage of initial powders are improved. Longer injection distance causes much energy to transfer to particles due to a longer residence time of powder in the high temperature zone. The high vitrification and decomposition degrees indicate that the new in-flight melting technology with 12-phase AC arc can substantially reduce the melting and refining time for glass production.

Laminar Flow and Heat Transfer in a Circular Tube Located behind a D.C.Arc Plasma Torch

Modeling results are presented for the laminar flow and heat transfer within a circular tube connected coaxially with a d c arc plasma torch. In order to determine the correct boundary conditions at the tube inlet, the computational domain is extended to include both the circular tube and the arc plasma torch. Computational results show that the gas static pressure in the tube increases at first and then decreases slowly, while the heat flux to the tube wall decreases monotonically with increasing distance from the tube inlet. Comparison of some computed results with corresponding experimental data is also given.

双相不锈钢脉冲电弧等离子体传热传质行为

基于电磁动力学、流体力学及热力学等理论以及高速摄像与电信号采集原位测试手段,考虑等离子体中的金属蒸汽行为建立电弧熔滴一体化多物理场耦合仿真模型,研究双相不锈钢脉冲电弧等离子体的传热传质行为。结果表明,电弧等离子体温度峰值分布在熔滴轴线两侧并与电流值呈正相关,在熔滴缩颈至过渡阶段,基板上表面由电弧等离子体的非对称性影响造成温度分布不均匀;电弧等离子体的流场分布结果与温度场类似,但不同时刻速度峰值除与电流值相关,还与熔滴的过渡状态有关,随着熔滴过渡进行,电弧等离子体的高温区和高速区皆向基板压缩;在熔滴缩颈之前,铁蒸汽随着电流增大逐渐向轴线压缩,在熔滴下方质量分数可以达到100%;在熔滴缩颈之后,熔滴上下的高浓度铁蒸汽会增大等离子体的电导率,进而促进熔滴过渡。

等离子体处理对雪纺织物数码印花正反面色差的影响

为了改善雪纺织物数码印花的正反面色差,防止在服装生产过程中出现擦白疵点,对等离子体处理过的雪纺织物进行数码印花并进行表征,结果表明:雪纺织物经等离子体处理后,纤维摩擦因数增大,使纱线间的摩擦力增大,降低了纱线位移的几率;织物比表面积增大,使印花上染百分率提高;织物润湿性、毛细效应和孔隙性增大,墨滴在织物表面的扩散面积减小,纵深渗透增大,使数码印花后织物正反面色差缩小。经生产实践应用,等离子体处理可改善加捻雪纺织物数码印花的擦白疵点。

旁路等离子-MIG复合电弧及耦合熔池作用机理与数值分析

旁路等离子-MIG复合工艺是通过等离子焊枪的导电铜嘴与焊丝之间形成的分流弧、焊丝与母材之间的主路弧同轴耦合进行焊接的新型工艺,不但保持了MIG焊的高效性,还可以通过对旁路电流的调节实现焊接过程能量的精确控制.为了深入了解该工艺条件下复合电弧与耦合熔池的物理作用机制,通过建立流体动力学瞬态计算模型,并基于合理的试验验证,对旁路电流加载前后气液两相内部及界面处的传热传质行为进行了对比研究.结果表明,相比未加载旁路电流时,电弧的最高温度下降约1000 K,同时电弧与耦合熔池交界处的有效热通量整体下降;熔池内部液态金属回流速度明显下降,因此导致熔深和熔宽尺寸均有所减少;复合电弧和耦合熔池的最大电磁力方向没有改变,但数值均有所降低.

铝合金与镀锌钢板CMT焊接过程传热传质现象的数值模拟

建立冷金属过渡(CMT)焊接的三维非稳态数学模型,研究铝合金和镀锌钢板CMT焊接过程的传热、传质现象,包括电弧等离子体的形成和变化、焊丝的送入与回抽、熔滴生长与过渡、熔池动态行为、镀锌层的蒸发及锌蒸气在电弧中的扩散。研究结果表明:在高温电弧的作用下钢板表面的镀锌层蒸发,锌蒸气由钢板表面向电弧区扩散,其分布受等离子体流动的影响。焊接过程中焊接电流、电弧长度不断变化,造成焊接工件表面附近的电弧压力持续变化。锌层蒸发增大了钢板表面附近的电弧压力,易造成熔滴过渡和焊接过程的不稳定。

磁控等离子体对尾喷管壁传热特性的影响

根据磁场作用下等离子体的湍流和传热能力将受到抑制的现象,提出利用磁场控制低温等离子体隔离高温燃气与喷管壁的方法,以减少高温燃气对壁面的传热,从而达到降低壁面温度的目的.分别建立诱导磁场方程求解洛伦兹力和磁场作用下的k-ε湍流模型求解湍流粘度,数值模拟了不同强度磁场作用下的磁控等离子体流动和传热特性.结果表明,磁场能够有效地抑制湍流强度,降低传热能力,从而有效地降低壁面温度;并且磁场越强,效果越明显.

等离子喷涂中粉末熔化过程的数值分析

研究了等离子喷涂过程中粉末粒子在等离子射流中的熔化过程，用有限差分法计算了不同物性参数的两种粉粒（铝和氧化锆）的固相加热和熔化过程，分析了等离子体温度、换热系数、粉粒直径和粉粒初始温度对粉粒熔化时间的影响，为优化工艺参数，提高涂层质量提供了理论依据。

低温等离子体技术预处理对稠油废水蒸发结垢的影响及其Visual Minteq分析

稠油废水低成本蒸发回收是实现稠油开采的重要环节。蒸发过程中生成硅垢和碳酸盐会严重影响传热,为了抑制蒸发过程污垢的生成,采用低温等离子体(NTP)技术对稠油废水预处理后再蒸发,并对污垢进行分析检测。利用Visual Minteq软件模拟来自2个油田的稠油废水经NTP预处理后蒸发垢的组分。结果表明,经过NTP预处理,稠油废水的硬度、二氧化硅含量、金属离子含量和pH值均降低;蒸发过程中污垢热阻降低,污垢组分中硅垢减少,但主要组分未发生改变。Visual Minteq模拟结果与XRD分析所得污垢组分基本吻合,验证了NTP预处理阻垢机理,即NTP预处理降低了稠油废水中碳酸钙、镁和钙组成的双正离子碳酸盐以及硅和镁组成的盐的饱和指数。

直流电弧等离子体炬的数值模拟研究

本文建立了直流电弧热等离子体炬的三维模型,利用流体动力学软件FLUENT对氮气热等离子体温度及速度的空间分布进行了数值模拟,并在此基础上研究了工作气体流量的变化对炬内热等离子体传热与流动特性的影响效应。研究结果表明:等离子体温度的最高值出现在阴极附近,并随着轴向距离的增加而减小;等离子体速度则随着轴向距离的增加而增加,在炬出口处达到其速度的极大值;工作气流量的增加对炬内的温度分布影响不大,但等离子体温度呈现出随工作气流量的增加而减小的趋势。