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US 12,096,547 B1Granted
High velocity plasma torch and method
OwnerVladimir E. Belashchenkoinventor
Life of this patent
Estimating the term…
Abstract
A high velocity plasma spray method and apparatus with relatively high plasma pressures of 3 bars or above. The preferable range of plasma pressure is 3 bars to 10 bars and a plasma enthalpy of preferably 10 KJ/g or above. The preferable enthalpy range is above 10 KJ/g and up to 20 KJ/g and the preferred specific power (Σ) is in the range of 16 KJ/g to 33 KJ/g.
Claims13
A method for depositing a coating from a plasma torch comprising:
- supplying a plasma torch including a cathode module having a cathode electrode, an anode module having an anode electrode having an anode axis, entrance zone and a cylindrical zone having diameter D1 wherein said plasma torch generates a plasma arc having an anode arc root attachment inside said anode;
- said plasma torch further including a first forming module (FM1) having a converging-diverging nozzle with a throat diameter Der and with an exit diameter D2 and a second forming module (FM2) positioned downstream of said first forming module and downstream of said anode arc root attachment;
- said second forming module controls one or more parameters of the plasma jet in said second forming module;
- an interelectrode module controlling a plasma arc passage between said cathode electrode and said anode electrode having one end adjacent said cathode module and a second end adjacent said anode module and having a pilot insert adjacent to said cathode;
- at least one neutral inter-electrode insert;
- said plasma torch further comprising two passageways to feed plasma gas in a total amount G;
- said plasma torch generating a voltage (U) above 150 V and current (I) below 500 A with a power W=U×I;
- supplying a feedstock into said plasma jet and depositing a coating on a substrate;
- wherein said plasma gas comprises more than 50 vol. % of molecular gas;
- wherein W/G is in the range of 16 KJ/g to 33 KJ/g;
- wherein plasma pressure is at or above 3 bars;
- wherein one of said passageways for feeding plasma gas comprises a first plasma gas passage located between said cathode and pilot insert for feeding plasma gas in amount G1 wherein said gas is directed through a plurality of orifices having a surface area S1 wherein a vortex is formed having a vortex intensity Vort1=G1/S1;
- wherein one of said passageways for feeding plasma gas comprises a second plasma gas passage located between said interelectrode module and said cylindrical part of anode for feeding plasma gas in an amount G2;
- wherein said gas is directed through a plurality of orifices having a surface area S2 wherein a vortex is formed having a vortex intensity Vort2=G2/S2;
- and
- wherein G2 flow rate is above 25 L/min;
- and
- wherein said Vort2 is greater than 0.4 g/((sec)(mm2)).
15 more elements
A plasma torch comprising:
- a cathode module having a cathode electrode, an anode module having an anode electrode having an anode axis, entrance zone and a cylindrical zone having diameter D1 wherein said plasma torch generates a plasma arc having an anode arc root attachment inside said anode;
- said plasma torch further including a first forming module (FM1) having a converging-diverging nozzle with a throat diameter Der and with an exit diameter D2 and a second forming module (FM2) positioned downstream of said first forming module and downstream of said anode arc root attachment;
- said second forming module controls one or more parameters of the plasma jet in said second forming module;
- an interelectrode module controlling a plasma arc passage between said cathode electrode and said anode electrode having one end adjacent said cathode module and a second end adjacent said anode module and having a pilot insert adjacent to said cathode;
- at least one neutral inter-electrode insert;
- said plasma torch further comprising two passageways to feed plasma gas in a total amount G;
- said plasma torch operates a voltage (U) above 150 V and current (I) below 500 A with a power W=U×I;
- wherein said plasma gas comprises more than 50 vol. % of molecular gas;
- wherein W/G is in the range of 16 KJ/g to 33 KJ/g;
- wherein plasma pressure is at or above 3 bars;
- wherein one of said passageways for feeding plasma gas comprises a first plasma gas passage located between said cathode and pilot insert for feeding plasma gas in amount G1 wherein said gas is directed through a plurality of orifices having a surface area S1 wherein a vortex is formed having a vortex intensity Vort1=G1/S1;
- wherein one of said passageways for feeding plasma gas comprises a second plasma gas passage located between said interelectrode module and said cylindrical part of anode for feeding plasma gas in an amount G2;
- wherein said gas is directed through a plurality of orifices having a surface area S2 wherein a vortex is formed having a vortex intensity Vort2=G2/S2;
- wherein G2 flow rate is above 25 L/min;
- and
- wherein said Vort2 is greater than 0.4 g/((sec)(mm2)).
13 more elements
Dependencies are inferred from the claim text.