Study of atmospheric plasma spray process with the emphasis on gas-shrouded nozzles

• Main Author: Jankovic, Miodrag M
• Format: Dissertation
• Language: English
• Subjects: plasma physics
• ISBN: 0612282848; 9780612282841

An atmospheric plasma spraying process is investigated in this work by using experimental approach and mathematical modelling. Emphasis was put on the gas shrouded nozzles, their design, and the protection against the mixing with the surrounding air, which they give to the plasma jet.
First part of the thesis is dedicated to the analysis of enthalpy probe method, as a major diagnostic tool in this work. Systematic error in measuring the stagnation pressure, due to a big temperature difference between the plasma and the water-cooled probe, is investigated here. Parallel measurements with the enthalpy probe and an uncooled ceramic probe were performed. Also, numerical experiments were conducted, using the k-$\varepsilon$ model of turbulence. Based on the obtained results, a compensating algorithm for the above error is suggested.
Major objective of the thesis was to study the plasma spraying process, and potential benefits from using the gas shrouded nozzles. Mathematical modelling was used to perform the parametric study on the flow pattern inside these nozzles. Two nozzles were used: a commercial conical nozzle, and a custom-made curvilinear nozzle. The later is aimed towards elimination of the cold air entrainment, recorded for the conical nozzle. Also, parametric study on the shrouding gas and its interaction with the plasma jet was carried out. Two modes of the shrouding gas injection were tested: through sixteen injection ports, and through a continuous slot, surrounding the plasma jet.
Both nozzles and both injection modes were thoroughly tested, experimentally and numerically. The curvilinear nozzle completely eliminates the cold air entrainment and yields significantly higher plasma temperature. Also, injection through the continuous slot resulted in a much better protection of the plasma jet. Both nozzles were used to perform the spraying tests. Obtained coatings were tested on porosity, adhesion strength, and micro-structure. These tests indicated better micro-structure of the coatings sprayed by the curvilinear nozzle. Also, their porosity was significantly lower, and the adhesion strength was higher for more than 25%. The overall results suggest that the curvilinear nozzles represent a much better solution for the gas shrouded plasma spraying.