Trajectories of titanium powder particles of diffferent size in a plasma flow

Abstract

The study focused on analyzing the trajectories of powder particles within a plasma flow, a process utilized for applying functional coatings and producing powders. An overview of contemporary scientific research dedicated to modeling these processes is presented. The primary objective of this study was to ascertain how the particle size of the powder, used as a raw material, influences the path of particles within a vertically directed plasma flow. We examined three sizes of titanium powder: 1 μm, 50 μm and 100 μm. These sizes were chosen based on production practices for the considered processes and the particle size distribution of the powder material used in full-scale experiments, employing specialized CAMSIZER-XT equipment. Our study reveals the significant impact of powder particle size on various parameters, including the opening angle, length, and width of the illuminated section of the plasma torch, as well as the distance traveled by particles entrained by the plasma flow from the plasma head. To investigate these effects, we conducted computer simulations, followed by validation through full-scale experiments for each case. Specifically, we employed the MAK-10 laboratory plasma facility at the Institute of Metallurgy, Ural Branch, Russian Academy of Sciences, which is designed for powder production and functional coatings. In order to ensure the reliability of our measurements, we performed statistical data processing of the full-scale experiment results using scatter plots and determination of their average values. The comparative analysis of results from both natural and computer experiments demonstrated a satisfactory level of convergence. This comparative analysis of three particle sizes of powder enabled us to formulate practical recommendations for enhancing equipment and process technology in the context of the considered procedures. Furthermore, our article introduces a computer model capable of predicting the dimensions of the reactor (the chamber for receiving powder materials), the optimal shape of components within the plasma facility, and the positioning of the substrate on which functional coatings are applied. This model can be applied to address similar problems within the scope of this study, facilitating the control of coating application processes and powder production.