Investigation of the Plasma Jet and the Powder Injection at a Cascaded, Single-Cathode, Atmospheric Plasma Spray Torch

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Prof. Dr.-Ing. Georg Mauer, g.mauer@fz-juelich.de, Forschungszentrum Jülich GmbH, IMD-2; Dr. Johannes C. Schmitt, jo.schmitt@fz-juelich.de, Forschungszentrum Jülich GmbH; Karl-Heinz Rauwald, k.-h.rauwald@fz-juelich.de, Forschungszentrum Jülich GmbH; Prof. Dr. Robert Vaßen, r.vassen@fz-juelich.de, Forschungszentrum Jülich GmbH; 

In atmospheric plasma spraying, the fluctuation of the plasma jet and the velocity of powder injection are important parameters affecting particle acceleration and heating. Additionally, the plasma gas flow often exhibits a swirl, which complicates the conditions. Diagnostic methods are necessary to study the behavior of the plasma jet and particles. In this study, images of the particle jet from one or two injectors of a cascaded single-cathode plasma torch were captured using a CCD camera in an Accuraspray 4.0 system. Brightness profiles at the spray distance were determined using digital image analysis. For double injection, a single feeder with a Y-branch in the powder line was used. The bimodal particle distributions changed position as the carrier gas flow rates varied. Experimentally obtained spray spots confirmed this. The carrier gas flows that minimize the distance between spray spots originating from the two injectors and optimize deposition efficiency were identified.

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March 2026

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