Effect of turbulence modulation on three-dimensional trajectories of powder particles in a plasma spray process

Shang, Shuo; Guduri, Balachandar; Cybulsky, M.; Batra, R.C.

doi:10.1088/0022-3727/47/40/405206

Cited by 10 publications

(16 citation statements)

References 60 publications

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“…The resulting plasma jet emanating from the nozzle outlet has the maximum temperature of ~ 14,000 K, and peak velocity of ~ 2.5 km/s at its centerline, and steep temperature and velocity gradients in the radial direction (~ 10 4 K/ mm and 5 × 10 5 /s) [3,4]. In general, micron-sized powder particles (~ 10-100 µm) and a carrier gas (typically Ar) are injected vertically downward through the powder port to reach the hot core of the plasma jet.…”

Section: Introductionmentioning

confidence: 99%

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Adaptive process control for achieving consistent particles' states in atmospheric plasma spray process

et al. 2021

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The coatings produced by an atmospheric plasma spray process (APSP) must be of uniform quality. However, the complexity of the process and the random introduction of noise variables such as fluctuations in the powder injection rate and the arc voltage make it difficult to control the coating quality that has been shown to depend upon mean values of powder particles’ temperature and speed, collectively called mean particles’ states (MPSs), just before they impact the substrate. Here, we use a science-based methodology to develop a stable and adaptive controller for achieving consistent MPSs and thereby decrease the manufacturing cost. We first identify inputs into the APSP that significantly affect the MPSs and then formulate a relationship between these two quantities. When the MPSs deviate from their desired values, the adaptive controller is shown to successfully adjust the input parameters to correct them. The performance of the controller is tested via numerical experiments using the software, LAVA-P, that has been shown to well simulate the APSP.

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Section: Introductionmentioning

confidence: 99%

“…The motivation, then, is to develop a stable and adaptive controller for an APSP to achieve the desired MPSs. The adaptive controller presented here has an adjustable tuning mechanism to cope up with effects of unknown [3]. Gases injected into the gas gun pass over the arc to form a plasma that exits the gun.…”

Section: Introductionmentioning

confidence: 99%

Adaptive process control for achieving consistent particles' states in atmospheric plasma spray process

et al. 2021

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“…It is in general well accepted that the shroud gas system leads to an improvement of the coating characteristics because it stabilizes the plasma conditions. The dynamics of this gas shielding shell in the Metco 9MB plasma jet consists of a swirling effect of the injected gases that is characteristic of each plasma torch geometrical design and is represented by a swirl number [8]. The swirl number has been previously defined as the ratio of angular to axial momentum in the heated gases, which has been the object of several studies [8][9][10][11].…”

Section: Introductionmentioning

confidence: 99%

“…The dynamics of this gas shielding shell in the Metco 9MB plasma jet consists of a swirling effect of the injected gases that is characteristic of each plasma torch geometrical design and is represented by a swirl number [8]. The swirl number has been previously defined as the ratio of angular to axial momentum in the heated gases, which has been the object of several studies [8][9][10][11]. For instance, the flow structure of a turbulent thermal plasma jet was studied by Spores et al to determine the swirl number [11].…”

Section: Introductionmentioning

confidence: 99%

Swirling Effects in Atmospheric Plasma Spraying Process: Experiments and Simulation

et al. 2020

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Experimental evidence of swirling effects in 3D trajectories of in-flight particles is presented based on static and dynamic footprints analysis as a function of stand-off distance of Al 2 O 3 deposited employing a Metco-9MB torch. Swirling effects were validated with a proprietary computational fluid dynamics (CFD) code that considers an argon-hydrogen plasma stream, in-flight particles trajectories, both creating the spray cone, and particle impact to form a footprint on a fixed substrate located at different distances up to 120 mm. Static and dynamic footprints showed that swirl produces a slight deviation of individual particle trajectories and thus footprint rotation, which may affect coating characteristics.

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“…A lot of three-dimensional simulations have been reported to study the complex arc movement and the in-flight particle trajectories (for example, Li and Pfender, 2007;Trelles, 2013;Shang et al, 2014;Alaya et al, 2015). However, only a few studies have been conducted focusing on in-flight particles in a plasma jet with externally applied magnetic field considering interaction between plasma structure and in-flight particles (Nishiyama et al, 1999;Sato et al, 2003).…”

Section: Introductionmentioning

confidence: 99%

Numerical analysis of in-flight particles in plasma jet with an externally applied magnetic field

Saito

Nakane

Fujino

et al. 2016

JFST

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In this work, three-dimensional, time-dependent magnetohydrodynamic (MHD) simulations of a direct-current (dc) plasma spray with an externally applied magnetic field are performed, and also the trajectories and heating histories of in-flight particles in a plasma spray jet are analyzed by Lagrangian method with one-way coupling between particle and plasma jet. The working gas is pure argon (Ar) and the material of in-flight particles is zirconium dioxide (ZrO 2 ). The representative values of operating current and magnetic flux density of externally applied magnetic field in this work are 350 A and 0.8 T, respectively. Numerical results obtained in the MHD simulation demonstrate that the use of externally applied magnetic field yields the rotation of the arc root on the anode. This rotation generates a plasma jet with a swirling component. Furthermore, it is shown from the numerical results that applying the magnetic field increases the operating voltage and thus boosts an amount of input power compared to the one without applying it. The analytical results of in-flight particles suggest that the impact positions of in-flight particles on the substrate in the case with the externally applied magnetic field change temporally due to the swirling component of the plasma jet, even when the injected position of particles is fixed. However, the utilization of externally applied magnetic field enhances heat transfer to particles, which leads to impacting of particles on substrate with well-molten state because of higher enthalpy plasma jet.

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Effect of turbulence modulation on three-dimensional trajectories of powder particles in a plasma spray process

Cited by 10 publications

References 60 publications

Adaptive process control for achieving consistent particles' states in atmospheric plasma spray process

Adaptive process control for achieving consistent particles' states in atmospheric plasma spray process

Swirling Effects in Atmospheric Plasma Spraying Process: Experiments and Simulation

Numerical analysis of in-flight particles in plasma jet with an externally applied magnetic field

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