U.S. patent number 3,684,911 [Application Number 05/066,852] was granted by the patent office on 1972-08-15 for plasma-jet generator for versatile applications.
Invention is credited to Luigi Belotti, Carmelo Caccamo, Giorgio Marcato, Giancarlo Perugini.
United States Patent |
3,684,911 |
Perugini , et al. |
August 15, 1972 |
**Please see images for:
( Certificate of Correction ) ** |
PLASMA-JET GENERATOR FOR VERSATILE APPLICATIONS
Abstract
Improvement of the plasma-jet generator described in U.S. Pat.
No. 3,390,292 to Perugini, by improving the water cooled anodic
surface, and an anode adapter using an interchangeable set of
electrodes forming and stabilizing the plasma-jets. This provided
higher cooling efficiency and higher operative resistance of the
anode and wider suitability of the generator in forming plasma-jets
of higher power and wider utility.
Inventors: |
Perugini; Giancarlo (Merano
(Bolzano), IT), Marcato; Giorgio (Bolzano,
IT), Belotti; Luigi (Merano (Bolzano), IT),
Caccamo; Carmelo (Merano (Bolzano), IT) |
Family
ID: |
22072128 |
Appl.
No.: |
05/066,852 |
Filed: |
August 25, 1970 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
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709677 |
Mar 1, 1968 |
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Current U.S.
Class: |
313/231.41;
219/74; 219/121.47; 219/121.72; 219/75; 219/121.49; 219/121.5;
313/23 |
Current CPC
Class: |
H05H
1/32 (20130101); B05B 7/226 (20130101) |
Current International
Class: |
B05B
7/16 (20060101); B05B 7/22 (20060101); H05H
1/32 (20060101); H05H 1/26 (20060101); H01d
017/26 () |
Field of
Search: |
;313/23,231
;219/74,75,121P |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Kominski; John
Parent Case Text
This invention is a continuation-in-part of application Ser. No.
709,677, filed Mar. 1, 1968 now abandoned and relates to an
improved plasma-jet generator having an anode of high resistance to
heat and being able to operate in a range of power densities from
0.5 up to 4.5 kW/mn.sup.2 and ratios of power/arc gas flow,
exceeding 10 and up to 30 kW/m.sup.3 /h.
Claims
We claim:
1. In a plasma-jet generator, comprising a cathode, an
interelectrodic electroinsulating element, an anode, said cathode
and anode being coaxial electrodes, means for injecting a stream of
water against the rear of the cathode, multiradial directrixes
determined by the rear configuration of the cathode for passage of
water to circumferential water passages in the electroinsulating
element for conveying the cooling water through said element to the
anode, said passages being coaxial to the electrodes and
equidirectional to the plasma-jet, and means for passing cooling
water around the anode to cool the same, and means for collecting
the water leaving out the anode into a circular discharge
collecting sump so that the water entering the anode and the
discharge collecting sump are adjacent each other though separated
from each other by an annular diaphragm supporting the anode; the
improvement comprising a resistant anode, which on an integral
copper body and in a coaxial position to a central nozzle, said
nozzle has a truncated conical ring of holes in a first portion of
said anode through which the cooling water flows circumferentially
coaxially and equidirectionally with the plasma-jet and with a
centripetal movement, then striking and cooling the inner wetted
surface of said anode and finally discharging through a transverse
groove, according to a multiradial centrifugal and oblique
direction, towards a discharge collecting sump.
2. The plasma jet generator of claim 1, wherein the anode is
substituted by an insert comprising at least two pieces, the first
of which is an anode adapter and the second of which is the true
anode, wherein at least the anode adapter, having in its center a
cylindrical or frusto-conical hole, is also provided with a double
frusto-conical ring of holes, the central hole and the rings of
holes being coaxial each other and to the plasma generator, in said
insert, so that the water coming from the interelectrodic
electro-insulating element is forced inside the holes of the inner
frusto-conical ring towards the anode, and is discharged from the
anode through the holes of the outer frusto-conical ring of the
anode adapter.
3. The insert according to claim 2, wherein the anode has holes and
grooves longitudinally placed in form of ring inside the body of
the anode and coaxially to the nozzle of the same, so that the
water flows through the holes equidirectionally with the plasma jet
and flows in the grooves countercurrently to the plasma jet.
4. The insert according to claim 2, wherein the anode has only a
transverse groove.
5. The plasma-jet generator of claim 1, wherein the internal
conformation generated by the electrodic inserts and in contact
with the arc gas presents a coaxial cylindrical cathode ending in
only one tip taper, within a conical part constituting the inside
of a cylindrical nozzle.
6. The plasma-jet generator of claim 5, wherein when using
plasma-jets originated by a noble gas, the taper of the cathode and
that of the nozzle are between 53.degree. and 63.degree., and
61.degree. and 71.degree., respectively.
7. The plasma-jet generator of claim 6, wherein the preferred taper
values of the cathode and of the nozzle are 58.degree. and
66.degree., respectively.
8. The plasma-jet generator of claim 7, wherein the tip of the
cathode is cone shaped and cropped with a bending radius between
0.75 and 1.5 mm.
9. The plasma-jet generator of claim 7, wherein the bending radius
is 1.25 mm.
10. The plasma-jet generator of claim 3, wherein when using
plasma-jets originated by a gas selected from nitrogen, hydrogen
and mixtures thereof, the taper of the cathode and that of the
nozzle are between 85.degree. and 95.degree., and 54.degree. and
64.degree., respectively.
11. The plasma-jet generator of claim 10, wherein the preferred
taper values of the cathode and of the nozzle are 90.degree. and
59.degree., respectively.
12. The plasma-jet generator of claim 4, wherein for use of
plasma-jets originated by gaseous mixtures selected from
argon/nitrogen and argon/hydrogen, the cathode taper and that of
the nozzle are between 35.degree. and 45.degree., and 18.degree.
and 22.degree., respectively.
13. The plasma-jet generator of claim 12, wherein the preferential
taper values of the cathode and of the nozzle are 40.degree. and
20.degree., respectively.
14. The plasma-jet generator of claim 13, wherein the cone-shaped
tip of the cathode is cropped with a flat face being normal with
respect to the axis of said cathode, said flat face having a
diameter comprised between 1.4 and 1.8 mm.
15. The plasma-jet generator of claim 14, wherein the diameter is
1.6 mm.
16. The plasma-jet generator of claim 8, wherein the position of
the cathode tip is coplanar with the beginning of a cylindrical
portion of the nozzle, within a variance of .+-. 2mm.
17. The plasma-jet generator of claim 11, wherein the position of
the cathode tip is coplanar with the beginning of a cylindrical
portion of the nozzle, within a variance of .+-. 2 mm.
18. The plasma-jet generator of claim 14, wherein the coaxial
assemblage of the cathode with respect to the nozzle is separated
at a distance between 5 and 10 mm.
19. The plasma-jet generator of claim 18, wherein the separation is
6 mm.
Description
Reference is made to the art of generating plasma-jets and of
employing the same in several technical applications. The present
invention relates to improvements of the plasma-jet generator
described in U.S. Pat. No. 3,390,292 to Perugini.
In a plasma-jet generator, comprising a cathode, an interelectrode
electro-insulating element and an anode (said cathode and anode
being coaxial electrodes), U.S. Pat. No. 3,390,292 to Perugini,
discloses a cooling system which comprises means for injecting a
stream of water against the rear of the cathode, multiradial
directrixes determined by the rear configuration of the cathode for
passage of water to circumferential water passages in the
electro-insulating element for conveying the cooling water through
said element to the anode, said passage being coaxial to the
electrodes and equidirectional to the plasma jet, and means for
passing cooling water around the anode to cool the same, said anode
has an axial nozzle which presents a series of parallel,
cylindrical and truncated-conical shapes obtained on an integral
copper body, multiradial directrixes in a first portion of said
anode through which the cooling water flows with a centripetal
movement and then along a main portion, with a water passage which
is circumferential coaxially, and equidirectional with the plasma
jet, and finally a ring of holes arranged radially and obliquely on
the external annular wall of the anode, an annular diaphragm
supporting the anode and a circular discharge collecting zone so
that the water entering the anode and the discharge collecting zone
are adjacent each other though separated from each other by said
annular diaphragm.
In the known art utilization of plasma-jets of non-transferred arc
type for spray procedures for producing protective coatings by a
gas shielded short electric circuiting arcing system, the
parameters, such as current density, power density, and ratio of
power/arc gas flow, appear to be contained below the following
values: 10 Amp/mm.sup.2 ; 0.5 kW/mm.sup.2 ; and 10 kW/m.sup.3 /h,
respectively, because if higher power is utilized, the arc gas flow
being unchanged, a damage can occur in the electrodes, while if the
arc gas flow is also made higher, the arc is modified to a gas
constricted long electric circuiting arcing inside the anodic hole,
and results in an excessive flow rate of the plasma-jet issuing.
Under these conditions, although the devices show a satisfactory
performance, the flow of flame in contact with the nozzle walls
does not possess a sufficiently high temperature for the fusion of
the material, particularly powdered material, passing through said
zones in the pronouncedly short retention times. This is
particularly the case where the arc gas flow is also made
higher.
It is an object of the present invention to provide an anode of
improved heat resistance in the plasma-generator of Perugini and to
make higher the plasma power obtainable by the generator. Other
objects are to make the device more handy and widen the practical
applications of the device in the several specific fields of plasma
technology.
It has now been found that the anode resistance can be increased
and the power of the plasma-jet made higher if the system,
according to which the water flows entering to the anode, is
modified so that the water can strike the anode surface more
vigorously.
The invention consists of a newly cooled anode, and more
particularly of a new anode design by which the position of the
ring of holes and of the groove in the anode is inverted, with
reference to the Perugini plasma generator, so that the water
coming from the interelectrodic electro-insulating element is
entering equidirectionally to the plasma-jet multiradially and
centripetally, through a ring of holes which is placed in the inner
part of the anode and coaxially to the plasma jet. In this way, the
water leaves the anode through a groove placed in the outer part of
the anode according to traverse position to the axis of the same
anode, so that the water flows multiradially centrifugally and in
opposite direction to the plasma jet towards a circular discharge
collecting sump. Another feature of the invention concerns the
substitution of the anode with an insert of at least two pieces,
the first of which is an anode adapter and the second of which is
the true anode. At least the adapter, having in its center a
cylindrical or frusto-conical hole, is provided with a double
frusto-conical ring of holes, the central hole and the rings of
holes being coaxial each other and to the plasma generator. The
water, coming from the interelectrodic electro-insulating element,
is forced inside the holes of the inner frusto-conical
(truncated-conical) ring, towards the anode, and is discharged from
the anode through the holes of the outer truncated-conical ring of
the anode adapter. The anode connected to the anode adapter may or
may not have holes and grooves longitudinally placed in form of
ring, inside the body of the anode and coaxially to the nozzle of
the same.
The special design of the anode adapter and/or of the anode assures
a surprising better anodic cooling effect by a better striking
action of the water against the surface of the anode.
By means of the anode adapter, different types of anodic inserts
can be coupled with the plasma generator which so reaches larger
possibilities in several specific plasma-jet applications.
The invention will be described in greater detail with reference to
the drawing, in which:
FIG. 1 shows in sectional view a plasma generator, in gun form
according to our invention, provided of cathode and anode
(interchangeable insert) for plasma arc of "non-transferred" type
and for spray operations. The insert is to be employed with the use
of noble gas (or noble gas mixtures) for blowing and stabilizing
the plasma-jet;
FIG. 2 shows a cross section of an interchangeable insert of which
the gun plasma generator of FIG. 1, is provided;
FIGS. 2A, 2B and 2C, show respectively, a cross section along line
AA of FIG. 2 and left and right views of FIG. 2;
FIGS. 3 and 4 show the extractability of the cathode from the front
and rear respectively;
FIGS. 5 and 6 show a sectional view of the plasma generator in head
shape at 90.degree. and at 45.degree. respectively;
FIGS. 7, 7A, 7B and 7C show, respectively, a cross section of
another interchangeable insert, a cross section along line AA and
left and right end views thereof; the insert comprises cathode,
anode, and anodic adapter for plasma arc of "non-transferred" type
and for "spray" operations. The insert is to be employed with the
use of nitrogen (or hydrogen or mixture thereof), for blowing and
stabilizing the plasma-jet;
FIGS. 8, 8A, 8B and 8C show, respectively, a cross section of still
another interchangeable insert, a cross section along line AA and
the left and right end views thereof; the insert comprises cathode,
anode, anodic adapter for plasma arc of "non-transferred" type and
for spraying plastic materials (named "Plastospray" operations).
The insert is to be employed with the use of nitrogen (or hydrogen
or nitrogen/hydrogen mixtures) for blowing and stabilizing the
plasma-jet;
FIGS. 9, 9A and 9B show, respectively, a cross section of another
interchangeable insert and the left and right end views thereof;
the insert comprises cathode, anode and anodic adapter for plasma
arc of "prevailingly transferred" type and for "rapid cut"
operations. The insert is to be employed with the use of argon gas
or argon/nitrogen or argon/hydrogen mixtures;
FIG. 10 shows a diagram for arc plasma of the "prevailingly
transferred" type;
FIG. 11 shows a diagram for arc plasma of the "totally transferred"
type; and
FIG. 12 shows a diagram for "non-transferred" arc plasma.
In greater detail the longitudinal section of the plasma generator
in the pistol type version of FIG. 1 is provided with the insert
shows separately in FIG. 2; FIG. 2A shows a section of the device
through section AA of FIG. 2; FIGS. 2B and 2C show the left and
right end views, respectively, of FIG. 2.
The upper part of cathode tube 1 of negative polarity, which
supplies continuous electrical current and cooling water, is welded
onto an obturator 2 of the cathode compartment. The obturator,
which seals the cathode compartment, is fastened, preferably by
screws, to the metal conical seat 3, which in turn is connected by
screws and/or threading to the interelectrodic electro-insulating
element 4, constituting an interchangeable insert. Thus the
obturator also acts as the cathode support. A portion of tube 1
protrudes along the axis of obturator 2 so that it injects water
into the groove of cathode 5, which is fixed to the inner wall of
obturator 2 by means of screw threads. The cathode can be advanced
up to 3 mm by simply inserting additional small washers in the
interface zone 6 until the initial clearance at 7 is eliminated, in
order to compensate for consumption of the tungsten tip during its
operating life. This increases the working life of the cathode and
accordingly reduces the depreciation of the cathode. The cooled
anode 13 has its maximum cylindrical dimension in the central
portion. This dimension forms the hydraulic seal with the "O" ring,
OR 2131. Thus the cathode can be extracted from either the front or
the rear of the interelectrodic electro-insulating body. This
greatly facilitates the inspection and the maintenance of the
cathode. FIGS. 3 and 4 show its double extractability. All figures
use the same numerals for the same feature. Returning to FIG. 1,
the other parts of the plasma generator are: The anti-radiation
template 8 of ceramic material which attenuates the surface
temperature on the walls of the arc gas chamber thus avoiding
alteration of the organic electro-insulating material 4; the anode
support 10 comprising the annular deflector 11 and the water
discharge collecting sump 12, the specially cooled anode 13; the
anode tightening ring 14 which distributes the auxiliary gas
(protective and cooling gas) delivered through tube 24 and expelled
through the ring of distributing holes 25; the powder injection
tube 16; water passages 32 and 33 for cooling the anode; anode tube
17 for the cooling water discharge and for the return of the
electrical current; tube 18 for the tangential injection of the gas
into the arc chamber; gas vortex chamber 19; the small auxiliary
electrode 20 for striking the arc by sparking on the anode with the
aid of an auxiliary electrical circuit. "O" rings OR 2100, OR 114,
OR 3193 and OR 3168 create efficient seals at various locations in
the device.
The external casing of the generator consists of a central part 9
fastened to the generator body by a screw on each side, at the
front, together with a ring at the rear tightening the generator
body by means of an interposed electro-insulating socket 7 having
the function of preventing the electrical contact with the cathodic
compartment. Fastened to the central casing 9 are a front cup 22
and a rear cup 23 provided with tongue 15 suitable for mechanically
attaching the plasma generator to a holder.
There is also the small tube 21 which is for injecting compressed
air for cooling the electro-insulating interelectrodic element. The
air jet, in fact, strikes the bottom of the electro-insulating
interelectrodic element, embraces the sides of its body, and then
goes upwards and passes out through the slit existing between the
upper part of the central casing 9 and the upper part of the anodic
support 10. In this way, the electro-insulating interelectrodic
element, which is the part most sensitive to the actions of
overheating, is cooled by the combined action of the water flow
inside the element and of the external flow of compressed air
circulating between the device casing and the external surface of
the interelectrodic electro-insulating element.
The plasma-jet generator may be constructed not only in the pistal
shape version, but also in head shape at 90.degree. or head shape
at 45.degree., as illustrated in FIGS. 5 and 6, respectively. With
these shapes the functional structure of the generator does not
vary although the exterior configuration especially in the lower
rear part is modified. For particular applications inside narrow
and deep parts, these versions are much more practical and handy
above all for mechanized operations. Further discussion of these
latter versions is superfluous since they have functionally been
described by the description for the pistol version which carries
the same numbers.
The generator is operated in any of its many operating embodiments
as follows: After having connected the generator to a source of
continuous current, by copper plaits arranged inside suitably
flexible rubber tubes with water circulation, and having sent water
into the circuit and selected gas for the arc chamber feeding, the
electrodes are put under electrical tension. A spark between the
small auxiliary electrode and the anode is then ignited to ignite
the arc with a plasma-jet coming out from the nozzle. Upon ignition
of the plasma, the voltage between the idling electrodes undergoes
a sudden diminution, whereas the current increases correspondingly.
The opening voltage for argon is about 70 Volts; for mixtures of
argon/nitrogen and argon/hydrogen, it is about 140 Volts, and for
hydrogen or nitrogen, it is about 280 Volts.
For the sake of clarity, several terms used in the specification
will be here defined.
a. "Spray" procedure is the process by which a metallic material
(from low-melting to refractory), a ceramic material or a mixture
thereof, is projected in molten state onto a metallic or
non-metallic surface to produce on said surface a protective
coating which adheres to the surface with a bond of prevailingly
mechanical nature. The material as a powder is injected into a
flame, i.e. "non-transferred" arc plasma-jet, within which it
undergoes the dynamic melting.
b. "Saldospray" is the analogous process relating to the deposition
of a metallic coating material on a metallic base material, wherein
the interfacial zone is characterized by pronounced or
predominating metallurgical bonds which are concreted in only one
stage, i.e. concomitantly with projecting the coating matter which
is deposited in molten state and is practically pore free. In this
process, the mechanical bonds are of secondary importance and in
some cases they are negligible with respect to the predominating
metallurgical bond. The projection, the fusion of the coating
matter and the metallurgical bond of the latter on the metal base
surface, are dynamically performed by utilizing the energy of the
"prevailingly transferred" arc plasma.
c. "Plastospray" procedure is a process similar to the "spray"
process but where the coating matter is of organic nature and more
precisely is a thermoplastic or thermosetting polymer which when
injected in the powder state within the flame-jet (i.e.
"non-transferred" arc plasma-jet) undergoes in the jet a dynamic
fusion and then deposits as a film coating on the surface of a
metallic or non-metallic body.
d. "Melt-cut" procedure is the process by which
non-electro-conducting materials are cut by localized melting with
the aid of the energy of the "non-transferred" arc plasma jet.
e. "Rapid-cut" procedure is the process by which electro-conducting
materials, especially more or less thick metal sheets or metal
parts in general, are cut or perforated at high rates by localized
melting utilizing the concentrated energy of the "transferred" arc
plasma which may have the function of pilot arc, so as to result in
either the case of "prevailingly transferred" arc or of "totally
transferred" arc.
In the "non-transferred" arc plasma, there is only one electrical
circuit wherein the entire current intensity is transmitted from
the cathode to the nozzle-shaped anode, through the plasma coming
out from the anode nozzle. The workpiece, which is subjected to the
plasma jet, doe s not form part of the electrical circuit. This is
shown in FIG. 12.
In the "totally transferred" arc plasma, there is also only one
electrical circuit. Here, however, all the current intensity is
transmitted from the cathode to the piece being processed which is
connected as anode through the plasma jet coming out from the
nozzle. In this case, the nozzle acts exclusively as constricting
element for the plasma column without forming part of the
electrical circuit according to FIG. 11.
A "mixed or coupled" arc plasma is obtained when both the nozzle
and the workpiece are anodes in the electrical circuit in two
parallel distinct lines. In the known art, such a connection
results in the constricting nozzle acting as an auxiliary pilot
anode according to FIG. 10. In said combination, 5-30 percent of
the total current passes through the auxiliary pilot anode, with
the remaining 95-70 percent of current being transferred to the
workpiece.
In any case, when the plasma-jet generating device is removed from
the workpiece, the transferred arc will cease whereas the pilot arc
remains. The transferred arc will light up again automatically with
the reverse action of reapproaching the piece being processed with
the device, by virtue of the pilot arc which acts as primer. Said
type of coupled-arc plasma is more appropriately called
"prevailingly transferred" arc plasma. In the known art, said
plasma type is used in particular in "rapid-cut," and "saldospray"
operations.
The first group of interchangeable inserts is shown assembled in
FIG. 1 and isolated in FIGS. 2, 2A, 2B and 2C. FIG. 2A shows the
section along line AA and FIGS. 2B and 2C show the left and right
hand end views, respectively. These inserts comprise the cathode 5,
the specially cooled anode 13, the anode locking ring 14 with tube
24 for auxiliary gas feeding, which gas is blown in from the ring
of holes 25, and tube 16 for feeding the coating matter. This group
is suitable for the "spray" and "saldospray" applications with
plasma-jets of noble gas, preferably argon. The other features of
this group of interchangeable inserts have been described with
respect to FIG. 1.
A second group of interchangeable inserts is shown in FIGS. 7, 7A,
7B and 7C. FIG. 7A shows the section along line AA and FIGS. 7B and
7C show the left and right hand end views, respectively. These
inserts comprise the cathode 5, the specially cooled anode 13, an
internal anode adapter 26, an external anode adapter 28, locking
ring 27, and a feeding tube for the coating matter 16, the other
features being the same as previously shown. This group of inserts
is suitable for "spray" applications with the use of non-noble gas
plasma-jets such as nitrogen and/or hydrogen, and preferably
nitrogen.
A third group of interchangeable inserts is shown in FIGS. 8, 8A,
8B and 8C. FIG. 8A shows the section along line AA and FIGS. 8B and
8C show the left and right hand end views, respectively. These
inserts comprise the cathode 5, the specially cooled anode 13, an
internal anode adapter 26, an external anode adapter 28, a locking
ring 27, a feeding tube 16 for the coating matter, a tube 24 for
delivery of auxiliary gas (nitrogen and/or air, preferably
nitrogen), said gas being blown in from a ring of milled channels
29, and from the external ring of openings 30. The other features
are as previously shown. This group of interchangeable inserts is
suitable for "plastospray" applications with the use of plasma-jets
of non noble gas consisting of nitrogen and/or hydrogen, preferably
nitrogen.
A fourth group of interchangeable inserts is shown in FIGS. 9, 9A,
and 9B. FIGS. 9A and 9B show the respective left and right end
views of FIG. 9. This group comprises the cathode 5, the specially
cooled anode 13, only one anode adapter 26, and a locking ring 27
which also has the function of distributing the auxiliary gas which
can be introduced through tube 24, fixed on the anode adapter, and
can be blown in through the ring of holes 31 which latter may also
be arranged on the front face of the anode nozzle 13. The other
features are the same as previously described. This fourth group of
interchangeable inserts is suitable for "rapid-cut" applications,
using as the arc gas argon or mixtures of argon/nitrogen and
argon/hydrogen, and preferably mixtures of argon/nitrogen
comprising 95-25 percent of argon and 5-75 percent of nitrogen,
with particular preference to the restricted range of 80-50 percent
of argon and 20-50 percent of nitrogen.
While in all four of the above-cited groups of inserts the geometry
of the water-cooled cathodic surfaces has remained the same as that
according to U. S. Pat. No. 3,390,292 (i.e. direct cathode cooling
by injection of the cooling water normally and centrally at the
cathode rear surface), the geometry of the cooled surfaces of anode
13 has been changed and improved so that the water is conveyed in
equicurrent with the plasma-jet and is forced onto holed heat
exchange surfaces 32 and 32' having cylindrical or conical
geometrical configuration, said surfaces being coupled with other
heat exchanging surfaces 33, 33' and 33", consisting of annular
groove or grooves through which groove or grooves the water is
directed towards the discharge, as is shown in FIGS. 2, 7, 8 and
9.
More particularly the anode (see FIGS. 1, 2, 2A, 2B and 2C) has
been improved according to a new design in which the position of
the ring of holes and of the groove, with reference to the anode of
U. S. Pat. No. 3,390,292, is inverted so that the water coming from
the interelectrodic electro-insulating element is entering,
multiradially circumferentially and equidirectionally to the
plasma-jet, through a ring of holes 32 which is placed in the inner
part of the anode, coaxially to the plasma generator. In this way
the water forced into the holes 32 reaches the anodic surfaces to
be cooled, developing a better cooling effect by more vigorous
striking action of the water jets, and finally leaves out through
the transverse groove 33, moving multiradially, centrifugally and
obliquely in a countercorrent to the plasma jet towards the
discharge collecting sump 12.
According to another object of the invention, the anode is
substituted with an insert of two pieces, the first of which is an
anode adapter while the second is the true anode. The anode can be
provided with a set of holes and grooves longitudinally placed in
form of ring inside the body of the anode and coaxially to the
nozzle of the same. With reference to the insert of FIGS. 9, 9A,
9B, the anode body 13 has no longitudinal holes or grooves, but
only one transverse groove 33. In the anode adapter 26 instead are
present a conical hole in the center and two distinct truncated
conical rings of holes which are coaxial each other and to the
central conical hole. Through the holes 32 of the inner conical
ring the water is forced reaching so the anode 13 and striking
vigorously the inner surfaces 32". After the U-turning in the
groove 33, the water leaves out to the discharge, passing in
opposite sense to plasma-jet through the holes 33" of the outer
conical ring of the anode adapter 26. In this way the anode 13
reaches a higher heat-resistance, because the anode adapter
develops a more efficient cooling action. Another advantage is that
plasma-jets of higher power may be developed.
With reference to the inserts of FIGS. 7, 7A, 7B, 7C and FIGS. 8,
8A, 8B and 8C, the anode body 13 has longitudinal holes 32',
longitudinal grooves 33' and transverse groove 33. Finally the
anode body 13 is covered in the right side by an external anode
adapter 28, and in the left side by the anode adapter 26. In the
anode adapter 26 are present a cylindrical hole in the center and
two distinct truncated conical rings of holes which are coaxial
each other and to the central cylindrical hole. The water coming
from the holes 32 of the inner truncated conical ring of the anode
adapter strikes into the holes 32', of the anode equidirectionally
with the plasma-jet and turning in the groove 33, flows in opposite
sense to plasma-jet through the longitudinal grooves 33' in the
anode, in countercurrent to the plasma-jet, leaving out the anode
by discharge through the holes 33" of the anode adapter 26. In this
way the cooling action of the water on the anode is made more
efficient and consequently higher the resistance of the anode.
Hereinafter, the geometry of the electrode surfaces, in contact
with the plasma-jet, will be described, in any insert, the tip
ending cathode is coaxially placed inside the conical part of the
nozzle.
For the group of inserts according to FIG. 2, suitable for noble
gas plasma-jets, preferably of argon, the tapers of the cathode and
of the nozzle are between 53.degree. and 63.degree., and between
61.degree. and 71.degree., respectively, and preferably 58.degree.
for the cathode and 66.degree. for the nozzle. In this group of
inserts, the conical end of the cathode is cropped, with a bending
radius between 0.75 and 1.5 mm, and preferably 1.25 mm.
For the group of inserts according to FIGS. 7 and 8, suitable for
nitrogen and/or hydrogen plasmas, preferably nitrogen plasma, the
tapers of the cathode and of the nozzle are between 85.degree. and
95.degree., and between 54.degree. and 64.degree., respectively,
and preferably 90.degree. for the cathode and 59.degree. for the
nozzle. For the group of inserts according to FIG. 9, suitable
preferably for mixed plasmas of argon/hydrogen or even more
preferably for argon/nitrogen, the tapers of the cathode and of the
nozzle are between 35.degree. and 45.degree., and between
18.degree. and 22.degree., respectively, and preferably 40.degree.
for the cathode and 20.degree. for the nozzle.
For the groups according to FIGS. 7, 8 and 9, the cathode taper is
crop-ended with a flat face, being normal with respect to the axis,
having a diameter comprised between 1.4 and 1.8 mm, preferably 1.6
mm. For the insert groups of FIGS. 2, 7 and 8, the distance at
which the cathode is tightened, within the nozzle taper, is such
that the cathode tip will appear coplanar with the beginning of the
cylindrical portion of the nozzle within a variance range of .+-. 2
mm. For the insert group of FIG. 9, on the other hand, the distance
at which the cathode is tightened, within the nozzle taper, is such
that the cathode tip is between 5 and 10 mm from the external tip
of the nozzle, and preferably 6 mm.
FIG. 10 shows a diagram for arc plasma for the "prevailingly
transferred" type. In this figure, line 101 shows the entry of
water and current into cathode compartment 105 while line 102 shows
the exit of water and current coming from anode compartment 106.
Also shown is anode line 103 which is connected to workpiece 114.
The interelectrode electro-insulator of the plasma-jet generator
device is shown at 104 between the cathode compartment 105 and
anode compartment 106. The auxiliary ignition electrode 107,
powered by ignition generator 108, which is fed by the alternate
electric current feed line 115, ignites the plasma generator per
se. At 109 is seen a variable rheostat with water cooling. The
resistance in this rheostat is made high so that the current will
pass on to line 103 to give a "prevailingly transferred" arc
plasma. At 110 is a connecting anode line and 111 is the line for
reentrance into electric current rectifying machine 113 fed by
three-phase alternating current feed line 116. The cathode line
from machine 113 is seen at 112.
In FIG. 11, which shows a diagram of "totally transferred" arc
plasma, those features referred to in FIG. 10 are equally
applicable. This figure has been modified in that a fuse 117 has
been inserted into the connecting anode line 110 which fuse, at
ignition of the plasma-jet, interrupts the passage of current
through the anode line 110 so that all can well pass through line
103 to the workpiece 114, being processed. Thus there is a "totally
transferred" arc plasma.
FIG. 12 relates to a diagram for a "non-transferred" arc plasma.
Again, those things stated as to FIG. 10 are equally applicable. It
should be noted, however, that workpiece 114 has no electrical
connection whatsoever thereto. Anode line 103 is connected to anode
line 102, cutting out rheostat 109 from the circuit. Line 110 is
also disconnected so that rheostat 109 is completely
disconnected.
The advantages obtained with the plasma-jet generator according to
our invention can be summarized as follows: the overall dimension
has been remarkably reduced so as to permit the use of the device
of the generator inside of small tubular elements, down to minimum
diameters of 110 mm and even smaller, when using the device in the
"head" version with plasma-jet at 45.degree.; moreover, the
inspection and the maintenance of the cathode has been improved
through the two-fold possibility of extracting it both from the
front and from the rear as is seen in FIGS. 3 and 4. Finally,
complementary air cooling has been combined with the water cooling
of the interelectrodic electro-insulating element of the Perugini
generator to provide a more efficient cooling of the element, which
is particularly delicate and sensitive to heat because it consists
of macromolecular organic material, and the possibility therefor of
employment in overheated working ambients.
The improvement in efficiency and elasticity of the use is obtained
by means of an interchangeable set of electrode groups, each group
comprising a cathode and a nozzle. Owing to the better cooling, the
plasma-jet generator is able to operate in a range of power
densities from 0.5 up to 4.5 kW/mm.sup.2, and with ratios of
power/arc gas flow, exceeding 10 and up to 30 kW/m.sup.3 /h.
The above-identified structures of the improved plasma-jet
generating device having high elasticity of operation, just by
virtue of their surprising functional capacity, allow distinct
applications characterized by more intense loads and densities of
energy, thus offering applications of greater practical utility.
Merely exemplifying and not limiting, we give hereinbelow examples
of the different applications of the improved generator. The main
operating data for these examples are summarized in table I. In
order to complete the data reported in table I, some details will
be given in what follows, relating to each of the examples and
referring to the type of application and to the result obtained in
each test, with respect to particular conditions of examination.
##SPC1##
EXAMPLE 1
A 0.25 mm thick coating of Al.sub.2 O.sub.3 was produced to give an
electrical insulation good even at 500.degree.C. After having kept
the thus prepared specimen in a muffle for 4 hours at the
temperature of 500.degree.C in air atmosphere, the degree of
electrical insulation was checked. The insulation was fully
positive when repeatedly touching the various zones of the applied
coating with the tips of an electrotecnical tester.
EXAMPLE 2
A 0.35 mm thick coating of ZrO.sub.2 stabilized with about 4.5% of
CaO was produced to give a barrier against heat oxidation,
resisting to actions of sudden thermal shock. The results was fully
positive since the prepared specimen withstands, without any damage
to the applied coating, a series of thermal shocks (more than 20),
carried out by directing from a distance of 5 cm an oxyacetylene
jet (0.275 l/sec. for C.sub.2 H.sub.2 ; 0.265 l/sec. for O.sub.2 at
17.degree.C and 746 mm Hg) on the front of the specimen and
bringing the temperature of the metal mass up to around
500.degree.C. At this point, a sudden direct jet of water at
15.degree.C was applied. This cylindrical succession of hot and
cold jets was repeated. The surface temperature of the ceramic
coating, when the metal mass had a temperature of 500.degree.C, was
about 1,500.degree.C at the central point hit by the oxyacetylene
jet.
EXAMPLE 3
A 0.5 mm thick coating of polyethylene material was produced to
provide a protection against corrosion from saline bath. The result
of the protection has appeared positive since the specimen remained
in perfect state both as to its immersed part and to the part
emerging from the saline bath during the corrosion tests wherein it
had been kept for over 1,000 hours at room temperature.
EXAMPLE 4
A 0.05-0.1 mm thick coating of chrome nickel 20-80 in the form of a
strip about 4-5 mm large, was formed during each pass on the base
element to which the coating matter binds itself by the surface
welding phenomenon. The coating thus achieved perfectly resists
bending in an arch having a 280 mm radius.
EXAMPLES 5, 6, and 7
The result of cutting different metals under consideration, appears
improved by the complete elimination of the burrs, in particular on
the lower borders, and by a cut wall which appears particularly
vertical in the cutting of stainless stell, and particularly smooth
in the cutting of copper.
* * * * *