R. J. Molz, E. Cotler, Sulzer Metco, Westbury, NY; F. Muggli, R. Waeger, Sulzer Innotec, Winterthur, Switzerland
Using the existing CFD and MHD modeling techniques pioneered at Sulzer Innotec, an F4 plasma gun was modeled with the addition of heat transfer to the modeling methodology. The heat transfer model extension considers both convective and radiation heat flux from the plasma plume into the gun components and then the water circuit. Certain assumptions and constraints were incorporated into the modeling methodology to enable the model to be used in an investigation of altering the heat flux within the gun body. Initial results provided considerable insight to the heat flow pattern within the F4 plasma gun and opportunity to improve the performance of the gun. Once the model was validated an optimization of the heat flow was conducted to improve the performance in terms of heat rejection to the water as well as peak temperatures of the anode (nozzle) and cathode (electrode). The results further demonstrate the feasibility of using computational models to improve and develop thermal spray devices.
Summary: An extension of the computational modeling of plasma guns to include heat transfer inside the gun and techniques to optimize the heat flow for improved gun performance.
