RUI/Collaborative Research: Investigation of Ion Currents in the Oxyfuel Cutting Flame and their Links to Critical Process Parameters

RUI/合作研究：氧燃料切割火焰中的离子电流及其与关键工艺参数的关系的研究

• 批准号: 1900698
• 负责人: Christopher Martin
• 金额: $ 17.36万
• 依托单位: Pennsylvania State Univ University Park
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2019
• 资助国家: 美国
• 起止时间: 2019-08-01 至 2023-07-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=1900698&HistoricalAwards=false
• 关键词: RUI; Collaborative; Research; Investigation; Ion

The award seeks to address serious persistent challenges in providing process feedback to better control and fully automate the oxyfuel cutting process. Though it is more than a century old, oxyfuel's (or 'flame-cutting's') unparalleled performance on thick steel has rendered it an enduring favorite in shipyards, building construction, rail, defense, and countless other heavy industries. The harsh operating environment (open flames, extreme heat) limit the ability of contemporary sensor suites to provide reliable data essential for process feedback control and automation. A potential solution to this problem is motivated by preliminary measurements demonstrating that electrical events called 'ion currents' associated with the flame itself can reliably indicate vital process states. The research will probe the underlying physics of the flame via modeling and experimental efforts. If successful the work could realize reliable cost-effective control and automation of the oxyfuel cutting process, a capability of great interest to many core US industries involved in construction, and major equipment manufacture for defense and energy applications. This is a collaborative research, whereby the experimental work will be undertaken at a predominantly undergraduate institute, while most of the modeling efforts will be conducted at the partner university. Engaging undergraduate students in industrially relevant research projects will hopefully encourage and promote advanced manufacturing beyond those immediately involved, and encourage broader participation. Collaboration with the partner university and the industrial partner, IHT-Automation, will also increase the workforce preparedness of both the graduate student and undergraduate students working on this project. This work tests the validity of a reduced-order ion transport model that considers standoff distance, work-surface/kerf chemical activity, and flame chemical activity with respect to the resulting current-voltage characteristic between the oxyfuel cutting torch and the workpiece. A novel spinning disc Langmuir probe technique will establish a spatially resolved map for the ion densities in the flame. Using these data as a reference, a multi-dimensional computational fluid dynamics simulation will be built on recently developed reduced chemical kinetic models to fully resolve the formation and transport of charged species throughout the flow. Subsequent analysis of the modeling and experimental results will validate or reject a highly simplified one-dimensional transport model relating the current-voltage characteristic of the flame to critical events. These include drift in standoff, ready-to-pierce, pierce success/failure, loss-of-cut prediction, drift in fuel/oxygen ratio, flameout, and potentially others.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.

该奖项旨在应对提供流程反馈以更好地控制和完全自动化氧气切割过程时的严重持续挑战。 尽管它已经有一个多世纪的历史了，但在厚厚的钢铁上（或“火焰切片”）的无与伦比的性能使其成为造船厂，建筑建筑，铁路，防御和其他无数重工业的持久最爱。 严酷的操作环境（空火，极高的热量）限制了当代传感器套房为过程反馈控制和自动化提供可靠数据的能力。 初步测量结果表明，与火焰本身相关的“离子电流”的电气事件可以可靠地表明生命过程状态，这是针对此问题的潜在解决方案。 该研究将通过建模和实验努力来探测火焰的基本物理。如果成功的话，这项工作可以实现可靠的成本效益控制和对氧化燃料切割过程的自动化，许多参与建筑业的核心行业引起了极大兴趣的能力以及用于国防和能源应用的主要设备。这是一项合作研究，实验性工作将在一个主要的本科研究所进行，而大多数建模工作将在合作伙伴大学进行。吸引本科生参与与工业相关的研究项目，有望鼓励和促进高级制造业，超越立即参与其中的制造业，并鼓励更广泛的参与。与合作伙伴大学和工业合作伙伴IHT-Automation合作还将增加研究生和本科生从事该项目的劳动力准备。 这项工作测试了一个减少订购离子传输模型的有效性，该模型考虑了隔距离距离，工作表面/kerf化学活动以及相对于氧燃料切割火炬与工件之间的电流 - 电压特性的火焰化学活性。 一种新型的旋转盘Langmuir探针技术将为火焰中的离子密度建立一个空间分辨的图。 使用这些数据作为参考，将建立多维计算流体动力学模拟，建立在最近开发的降低的化学动力学模型上，以充分解决整个流动中带电物种的形成和运输。 随后对建模和实验结果的分析将验证或拒绝高度简化的一维运输模型，该模型将火焰的电流 - 电压特征与关键事件有关。 其中包括僵局，现成的领域，皮尔斯成功/失败，切割预测丧失，燃料/氧气比率的漂移，燃烧率以及可能的其他可能性。该奖项反映了NSF的法定任务，并被认为是值得通过基金会的知识分子优点和更广泛的审查标准通过评估来通过评估来支持的。

项目成果

Simulation of Ion Current in Oxyfuel Flame Subject to an Electric Field

电场作用下富氧火焰中离子电流的模拟

• DOI: 10.1115/imece2020-24601
• 发表时间: 2020
• 期刊: International Mechanical Engineering Congress and Exposition
• 作者: Xu, Kemu;Untaroiu, Alexandrina;Martin, Christopher
• 通讯作者: Martin, Christopher

A one-dimensional model for ion transport in a flame with two absorbing surfaces

• DOI: 10.1080/13647830.2020.1826581
• 发表时间: 2020-09
• 期刊: Combustion Theory and Modelling
• 影响因子: 1.3
• 作者: Christopher R. Martin;A. Untaroiu;Kemu Xu

Role of Secondary Ions on the i-v Characteristics of Oxyfuel Flame Subject to an Electric Field

二次离子对电场作用下富氧火焰 i-v 特性的影响

• DOI: 10.1115/1.4056845
• 发表时间: 2023
• 期刊: Journal of Fluids Engineering
• 作者: Untaroiu, Alexandrina;Rahman, S. M.;Martin, Christopher R.
• 通讯作者: Martin, Christopher R.

Ions in the oxyfuel cutting flame due to work piece carbon

由于工件碳而导致火焰切割火焰中的离子

• DOI: 10.1016/j.mfglet.2022.12.008
• 发表时间: 2023
• 期刊: Manufacturing Letters
• 影响因子: 3.9
• 作者: Martin, Christopher;Oswald, Devin;Rahman, S.M. Mahbobur;Untaroiu, Alexandrina
• 通讯作者: Untaroiu, Alexandrina

Simulating the Effect of Electric Bias Voltages on the Electrical Characteristics of Oxyfuel Preheat Flame Using Reduced Combustion Mechanism

利用还原燃烧机制模拟电偏压对富氧预热火焰电特性的影响

• DOI: 10.1115/1.4062963
• 发表时间: 2023
• 期刊: Journal of Fluids Engineering
• 作者: Rahman, S. M.;Warrier, Rohith;Untaroiu, Alexandrina;Martin, Christopher R.
• 通讯作者: Martin, Christopher R.