Experimental study on the life and performance of an improved DC arc plasma torch

Abstract A novel DC arc plasma torch is designed in this paper in order to reduce the electrode erosion, and a series of experiments are carried out to investigate how to improve the lifetime and performance of the nitrogen DC arc plasma torch. The analysis of voltage characteristics of the plasma torch indicates that the interelectrode insert can increase the average arc voltage and the sudden expansion structure can reduce the voltage fluctuation, which is helpful to improve the working stability to some extent. The spectrum characteristics at the plasma torch outlet and the cold flow simulations show that the dual shielding gas mainly act near the anode and can effectively cover the entire anode wall. Combining the shielding gas distribution with anode heat transfer processes in argon and nitrogen plasma torch, it is inferred that argon shielding gas plays an important role on reducing the anode heat transfer processes in nitrogen plasma torch, which can effectively suppress the anode erosion. The life testing experimental results find that there is no significant erosion of the cathode, anode, and interelectrode insert after cumulative working time exceeding 20 h. The maximum nitrogen plasma jet length can reach ∼35 mm with the outlet jet temperature of about 20 000 K at the current of 100 A and nitrogen gas flow rate of 10 slm. The maximum average specific enthalpy and thermal efficiency are respectively about 14 MJ kg −1 and 75% in the nitrogen plasma torch. Therefore, this newly designed DC arc plasma torch not only can suppress the electrode erosion but also has good working performance, which is expected to have excellent application prospects.