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Influence of Nozzle Diameter on Electric Arc Dynamics and Coating Properties in a Cascaded-Anode Plasma Torch

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Abstract

Electric arc dynamics in plasma torches have an influence of the plasma jet stability and could impact coating properties. Depending on the plasma torch design, arc voltage fluctuations may vary from a hundred to only a few percent of the mean arc voltage. A cascaded-anode plasma torch particularly leads to very low arc voltage fluctuation, due to the presence of neutrodes limiting the amplitude of arc fluctuations. However, the electric arc dynamics and electrode erosion process are still poorly understood in this kind of plasma torches. The aim of this work is to refine the knowledge on the influence of the nozzle’s diameter on electric arc dynamics and on zirconia-yttria coating properties. Two plasma-forming gas compositions were studied, connecting several analysis methods (end-on imaging, arc current and arc voltage time monitoring, plasma light fluctuations at nozzle exit, thermal balance evaluation and in-flight particles assessment) to coatings characterization (porosity and hardness measurements). Reducing the nozzle’s diameter from 9 to 6.5 mm results in higher arc voltage fluctuations and lower thermal efficiency of the plasma torch. This is due to the warm plasma gas being more evenly distributed in the anode nozzle. After testing, surveys of the 6.5-mm-diameter nozzle show significant longitudinal wear, which may highlight an axial movement of the electric arc on the anode’s surface, leading to high arc voltage fluctuations. Finally, the particle velocity is higher in a 6.5-mm-diameter nozzle, resulting in a lower particle temperature and a higher coating porosity.

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Authors and Affiliations

  1. University of Limoges, CNRS, IRCER UMR 7315, F-87000, Limoges, France

    Céline Ruelle, Simon Goutier, Vincent Rat, Geoffroy Rivaud, Alan Kéromnès & Christophe Chazelas

  2. CEA, DAM, Le Ripault, F-37260, Monts, France

    Érick Meillot

Authors
  1. Céline Ruelle
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  2. Simon Goutier
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  3. Vincent Rat
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  4. Geoffroy Rivaud
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  5. Alan Kéromnès
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  6. Christophe Chazelas
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  7. Érick Meillot
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Correspondence to Céline Ruelle.

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This article is an invited paper selected from presentations at the 2023 International Thermal Spray Conference, held May 22-25, 2023, in Québec City, Canada, and has been expanded from the original presentation. The issue was organized by Giovanni Bolelli, University of Modena and Reggio Emilia (Lead Editor); Emine Bakan, Forschungszentrum Jülich GmbH; Partha Pratim Bandyopadhyay, Indian Institute of Technology, Karaghpur; Šárka Houdková, University of West Bohemia; Yuji Ichikawa, Tohoku University; Heli Koivuluoto, Tampere University; Yuk-Chiu Lau, General Electric Power (Retired); Hua Li, Ningbo Institute of Materials Technology and Engineering, CAS; Dheepa Srinivasan, Pratt & Whitney; and Filofteia-Laura Toma, Fraunhofer Institute for Material and Beam Technology.

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Ruelle, C., Goutier, S., Rat, V. et al. Influence of Nozzle Diameter on Electric Arc Dynamics and Coating Properties in a Cascaded-Anode Plasma Torch. J Therm Spray Tech 33, 756–770 (2024). https://doi.org/10.1007/s11666-023-01706-y

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  • DOI: https://doi.org/10.1007/s11666-023-01706-y

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