Application of functional coatings by supersonic thermal plasma flows

Development of modern high-speed technologies for thermal spraying proves that deposition of high-quality dense coatings requires velocity of sprayed particles to be 600 m/s and above. Plasma spraying is the most versatile and highly productive deposition method of various functional coatings without any limitations on the melting points of the sprayed materials. Present work describes a DC plasma torch designed for operation in a supersonic mode. The supersonic plasma torch features de Laval nozzle, utilization of air as a plasma-forming gas, and annular injection unit for delivery of the powder to the plasma jet. The comparison of NiCr and NiAl coatings deposited both in subsonic and supersonic modes are presented. Methods for further increasing the sprayed particles’velocity and the requirements for their heating temperature are proposed.

Application of Prandtl’s Theory in the Design of an Experimental Chamber for Static Pressure Measurements

Pumping in vacuum chambers is part of the field of environmental electron microscopy. These chambers are separated from each other by a small-diameter aperture that creates a critical flow in the supersonic flow regime. The distribution of pressure and shock waves in the path of the primary electron beam passing through the differentially pumped chamber has a large influence on the quality of the resulting microscope image. As part of this research, an experimental chamber was constructed to map supersonic flow at low pressures. The shape of this chamber was designed using mathematical–physical analyses, which served not only as a basis for the design of its geometry, but especially for the correct choice of absolute and differential pressure sensors with respect to the cryogenic temperature generated in the supersonic flow. The mathematical and physical analyses presented here map the nature of the supersonic flow with large gradients of state variables at low pressures at the continuum mechanics boundary near the region of free molecule motion in which the Environmental Electron Microscope and its differentially pumped chamber operate, which has a significant impact on the resulting sharpness of the final image obtained by the microscope. The results of this work map the flow in and behind the Laval nozzle in the experimental chamber and are the initial basis that enabled the optimization of the design of the chamber based on Prandtl’s theory for the possibility of fitting it with pressure probes in such a way that they can map the flow in and behind the Laval nozzle.

The Behavior of Supersonic Jets Generated by Combination Gas in the Steelmaking Process

In the duplex steelmaking process, the oxygen flow rate is suppressed to reduce the increasing rate of the temperature in the molten bath, resulting in severe dynamic conditions. To improve the mixing effect of the molten bath, a Laval nozzle structure designed for combination gas has been proposed. In this research, five types of Laval nozzle structure have been built based on the combination gas content, and both numerical simulations and experiments are performed to analyze the flow field of the supersonic jet. The axial velocity and oxygen concentration were measured in the experiment, which agreed well with the numerically simulated data. The results show that both initial axial velocity and potential core length increase with the flow rate of combination gas. Further, applying a higher N2 flow rate could improve the oxygen utilization rate at different ambient temperatures, but this issue increases the oxygen utilization rate; however, the latter can be reduced at higher ambient temperatures.