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Controlling Spray Torch Fluid Dynamics—Effect on Spray Particle and Coating Characteristics

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Abstract

In order to identify means to improve plasma spray consistency, various modifications to the design of a commercial plasma torch nozzle have been investigated. The modifications consist of preparing anode inserts with grooves in the axial direction (spline insert), and introducing a fraction of the plasma gas through a ring of micro-nozzles surrounding the anode nozzle (micro-jet ring). Different designs for each modification have been investigated, and these modifications have also been paired with a modified upstream gas injector. For each of the modified designs, a wide range of characteristics have been measured for the arc, the plasma jet, the in-flight particles, and the coating. The results show that most nozzle modifications lead to higher particle temperatures and velocities. The plasma jet is significantly elongated by using some of the modified nozzles, and the cold gas entrainment somewhat reduced. Each of the nozzle modifications can be easily implemented offering an economical way to enhance process reliability.

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Acknowledgment

Part of this research was funded by a grant from NSF grant number CTS-0317429.

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Authors and Affiliations

  1. Tecnomare SpA, Via Enrico Caviglia 11, 20139, Milano, Italy

    Lorenzo Vincenzi

  2. Toshiba Corp Power Systems, 8, Shinsugita-Cho, Isogo-Ku, Yokohama, 235-8523, Japan

    Sho Suzuki

  3. General Electric Corp., 1631 Bentley Parkway South, Minden, NV, 89423, USA

    David Outcalt

  4. University of Minnesota, 111 Church Str. SE, Minneapolis, MN, 55455, USA

    Joachim Heberlein

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  1. Lorenzo Vincenzi
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  2. Sho Suzuki
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  3. David Outcalt
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  4. Joachim Heberlein
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Correspondence to Joachim Heberlein.

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Vincenzi, L., Suzuki, S., Outcalt, D. et al. Controlling Spray Torch Fluid Dynamics—Effect on Spray Particle and Coating Characteristics. J Therm Spray Tech 19, 713–722 (2010). https://doi.org/10.1007/s11666-010-9478-z

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  • DOI: https://doi.org/10.1007/s11666-010-9478-z

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