Design and Optimization of Plasma Torch

Abstract

Presence of plasma technology in the industrial sector is becoming more evident now days. There has been a very significant growth in the employment of high power plasma torches in last decade, while the growth of low power plasma torches for cleaning, cutting, welding, material deposition etc had been steady since their introduction in 1950s.

In Institute for Plasma Research, the plasma applications are studied under various situations and thermonuclear energy generation is achieved. However in association with Facilitation Centre for industrial Plasma technology (FCIPT), IPR is trying to give solution to industrial needs.

Project is planned for development of atmospheric pressure plasma torch. The work includes design of plasma torch for low wattage. In this the heat transfer on each component is studied and the various electrodes are designed. Special attention will be given to include the proper swirl in the flow which will decide the maximum temperature, velocity and the jet length. The inclusion of swirl will give voltage and current stabilization in the region where arc is struck. The torch will be tested in DC and AC mode.

The different experiments on torch using different gases such as argon, nitrogen, air, helium etc. are carried out and results are analyzed. Use of air with DC supply gave better results compared to other gases in DC and AC supply. Experiments included cleaning (degreasing, oil cleaning), etching, and surface activation. The results are satisfactory and encouraging.

Besides modeling of the torch in CATIA (V5R16), analysis was done using finite element software ANSYS. The experimental results are validated using analysis. The work will help to dig more into the technology and exploit the ways to achieve perfect application.