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.

该奖项旨在解决在提供过程反馈方面持续存在的严重挑战，以更好地控制和完全自动化火焰切割过程。 尽管富氧燃烧（或“火焰切割”）已有一个多世纪的历史，但其在厚钢板上无与伦比的性能使其成为造船厂、建筑施工、铁路、国防和无数其他重工业的持久宠儿。 恶劣的操作环境（明火、极热）限制了现代传感器套件提供过程反馈控制和自动化所必需的可靠数据的能力。 该问题的潜在解决方案是通过初步测量来证明与火焰本身相关的称为“离子电流”的电事件可以可靠地指示重要的过程状态。 该研究将通过建模和实验努力探索火焰的基本物理原理。如果这项工作成功，可以实现富氧切割过程的可靠且经济有效的控制和自动化，这是美国许多涉及建筑、国防和能源应用的主要设备制造的核心行业非常感兴趣的能力。这是一项合作研究，实验工作将在以本科生为主的研究所进行，而大部分建模工作将在合作大学进行。让本科生参与工业相关的研究项目将有望鼓励和促进直接参与的先进制造业的发展，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 的合作也将提高从事该项目的研究生和本科生的劳动力准备。 这项工作测试了降阶离子传输模型的有效性，该模型考虑了远离距离、工作表面/切口化学活性和火焰化学活性，以及​​火焰切割炬和工件之间产生的电流-电压特性。 一种新颖的旋转盘朗缪尔探针技术将为火焰中的离子密度建立空间分辨图。 以这些数据为参考，将在最近开发的简化化学动力学模型的基础上建立多维计算流体动力学模拟，以完全解决整个流动中带电物质的形成和传输问题。 对建模和实验结果的后续分析将验证或拒绝将火焰的电流-电压特性与关键事件相关联的高度简化的一维传输模型。 其中包括对峙漂移、准备穿孔、穿孔成功/失败、切割损失预测、燃料/氧气比漂移、熄火以及其他潜在问题。该奖项反映了 NSF 的法定使命，并被认为值得支持通过使用基金会的智力优点和更广泛的影响审查标准进行评估。

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.