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<p>To minimize arc voltage fluctuations, it is imperative to restrict the arc movement. Cascaded plasma torch configurations have been developed to achieve this objective. The modular torch, employed in this study, represents one of the new designs. Featuring a specific configuration, different nozzle structures (length and inner diameter) can be used. This research aims to investigate experimentally the effects of particle characteristics (velocity and temperature) and powder mass flow rate on coating properties (microstructure, hardness, porosity, deposition efficiency). After analyzing the influence of torch geometry and operating parameters on particle characteristics, the careful selection of operating parameters, such as the geometry and the powder mass flow rate, can result in different coatings microstructures with a processing time reduced by 40 to 50% when feeding powder from 30 to 60&#xa0;g/min. The findings demonstrate that increasing powder mass flow rate can (1) decrease processing time by 2 without compromising coating quality (approximately 2.5% porosity, hardness higher than 1000HV<sub>0.3</sub> at 60&#xa0;g/min) compared to conventional torches (approximately 3% porosity, hardness of 1026HV<sub>0.3</sub>) and (2) enhance torch deposition efficiency (by approximately 10%).</p>

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Optimizing a Modular Cascaded Plasma Torch to Manufacture Dense Alumina Coatings with High Spray Efficiency

  • 期刊论文

  • 发表日期：

    2026年3月5日

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  • Myriam Sleiman,
  • Geoffrey Darut,
  • Ralph Seulin,
  • Marie Pierre Planche,
  • Jean-Jacques Gonzalez,
  • Pierre Freton,
  • Francis Sambou,
  • Armando Salito,
  • Manfred Rösli

摘要

To minimize arc voltage fluctuations, it is imperative to restrict the arc movement. Cascaded plasma torch configurations have been developed to achieve this objective. The modular torch, employed in this study, represents one of the new designs. Featuring a specific configuration, different nozzle structures (length and inner diameter) can be used. This research aims to investigate experimentally the effects of particle characteristics (velocity and temperature) and powder mass flow rate on coating properties (microstructure, hardness, porosity, deposition efficiency). After analyzing the influence of torch geometry and operating parameters on particle characteristics, the careful selection of operating parameters, such as the geometry and the powder mass flow rate, can result in different coatings microstructures with a processing time reduced by 40 to 50% when feeding powder from 30 to 60 g/min. The findings demonstrate that increasing powder mass flow rate can (1) decrease processing time by 2 without compromising coating quality (approximately 2.5% porosity, hardness higher than 1000HV0.3 at 60 g/min) compared to conventional torches (approximately 3% porosity, hardness of 1026HV0.3) and (2) enhance torch deposition efficiency (by approximately 10%).