Increasing the energy efficiency of plasma spraying by means of simulation-based process development

通过基于模拟的工艺开发提高等离子喷涂的能源效率

• 批准号: 442323795
• 负责人: Professorin Dr.-Ing. Kirsten Bobzin
• 金额: --
• 依托单位: Institut für Oberflächentechnik (IOT)
• 依托单位国家: 德国
• 项目类别: Research Grants
• 财政年份: 2020
• 资助国家: 德国
• 起止时间: 2019-12-31 至 2023-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/442323795?language=en
• 关键词: Increasing; energy; efficiency; plasma; spraying

Plasma spraying is one of the most important process variants in thermal spraying. At present, only a small part of the available energy is used to accelerate and melt the particles. A promising solution for increasing energy efficiency is a solid shroud that surrounds the plasma free jet and thus prevents mixing with the ambient air. As a result of this separation, the plasma temperature can be increased, thereby raising the energy efficiency. Another expected positive effect is the prevention of oxidation of the spray particles and thus the coatings.The primary goal of the project is to investigate the potential to increasing the energy efficiency of the plasma spraying process by using a solid shroud. In this project a methodology will be developed to design such a shroud and to optimize its geometry for given process parameters. Ideally, this solid shroud also increases the plasma stability of the plasma jet and thus the process stability. Therefore, a further goal is to investigate the effects of a solid shroud on the plasma stability. In addition to energy efficiency, a solid shroud also offers great potential for improving coating properties. Consequently, the possible influence on the coating properties will be investigated. In order to achieve these goals, a numerical simulation model of a plasma generator with a solid shroud will be developed based on a model of previous DFG projects. By using modern algorithms, such as particle swarm optimization and evolutionary algorithms, the geometry of the solid shroud is then calculated and optimized. The effects of the nozzle extension on plasma stability will be investigated by high-speed videography of the plasma free jet and high-resolution current and potential measurements. For these, appropriate measuring equipment is requested as part of this proposal. In experimental tests the effect on the energy efficiency and on the coating properties will be determined for the spray materials Al2O3 and MCrAlY.In the third year of the research project, a further approach to increasing energy efficiency, preheating of the spray particles, will be investigated. By exploiting the radiation of the plasma jet, the particles can be preheated without the need for an external source of energy. With the help of numerical simulations and experiments, such a preheating device will be designed and its potential to increase the energy efficiency will be determined. A combination of a solid shroud and a particle preheating will also be examined in detail this third year.

血浆喷涂是热喷涂中最重要的过程变体之一。目前，只有一小部分可用能量用于加速和融化颗粒。提高能源效率的有前途的解决方案是围绕缺乏血浆的射流的固体裹尸布，从而防止与环境空气混合。由于这种分离，可以提高等离子温度，从而提高能源效率。另一个预期的积极作用是预防喷雾颗粒和涂料的氧化。该项目的主要目标是研究使用固体裹尸布提高等离子体喷涂工艺的能效的潜力。在此项目中，将开发一种方法来设计这样的裹尸布并为给定的过程参数优化其几何形状。理想情况下，这种固体裹尸布还增加了等离子体喷射的血浆稳定性，从而增加了过程稳定性。因此，另一个目标是研究固体裹尸布对等离子体稳定性的影响。除了能源效率外，固体裹尸布还提供了改善涂料特性的巨大潜力。因此，将研究对涂层特性的可能影响。为了实现这些目标，将根据先前的DFG项目的模型来开发具有固体罩的等离子体生成器的数值模拟模型。通过使用现代算法，例如粒子群优化和进化算法，然后计算和优化实心裹尸布的几何形状。喷嘴扩展对等离子体稳定性的影响将通过缺乏血浆射流以及高分辨率电流和潜在测量值的高速摄影进行研究。对于这些，作为本提案的一部分，请求适当的测量设备。在实验测试中，将对研究项目的第三年进行喷雾材料AL2O3和MCRALY的能源效率和对涂层的影响，这是一种进一步提高能源效率的进一步方法，可以研究喷雾颗粒的预热。通过利用等离子射流的辐射，可以预热颗粒而无需外部能源。借助数值模拟和实验，将设计这种预热装置，并确定其提高能源效率的潜力。在本三年还将详细研究实心裹尸布和颗粒预热的组合。