臺灣博碩士論文加值系統

本研究利用計算流體力學探討大氣電漿熔射製備陶瓷膜時，其熔射粒子飛行軌跡與受熱之關係。大氣電漿熔射技術目前廣泛應用於工業界，主要以製備無機膜為主要方向，而電漿熔射形成塗層的過程中，影響塗層孔隙度的關鍵就在於粒子的飛行速度與熔融狀態，如何使粒子沿著火焰的高溫處移動是重要的因素。過去有許多學者利用線上偵測儀器(on-line monitor)觀察粒子在飛行過程中的熔融狀態，但是由於粒子的滯留時間極為短暫，對於粒子在飛行過程中其他資訊很難完全從儀器去取得。因此本研究以商業軟體FLUENT模擬不同載氣流量對電漿射流的影響，並以離散相模型探討氧化鋁粉末在高溫電漿的飛行速度與其熔融狀態之關係。
本文內容針對載氣流量對粒子飛行速度、受熱過程與滯留時間之影響。研究發現電漿射流受到載氣流量的影響，造成噴塗角(spray-angle)會產生偏移的現象。內送粉系統因靠近電弧氣體入口，所以對射流的作用比外送粉系統來的更明顯，且每提高1 SLM就會導致射流偏移中心線1° 。隨著載氣流量的提高，射流的最大速度逐漸上升，而溫度則是受到速度的影響呈現下降的趨勢。
內送粉系統粉末的飛行速度與表面溫度較高，粉末入射的位置屬於溫度上升之處，飛行距離長，使得粉末受熱時間較長；在外送粉系統下，粉體入射的位置屬於溫度下降的地方，粉末在電漿射流受熱時間不夠長，導致未熔融粉末的數目普遍較內送粉來的多。分析粒子的熔融狀態時發現，即使粒子的表面溫度高於熔點，粒子的中心處仍然會有未熔融的情況產生，粒子中心點的溫度與表面溫度有14％ 的差距。而粒子揮發現象在本研究中則因為粒子滯留時間低於揮發所需要的時間，並沒有發生揮發現象。
不同載氣流量下，不同粒徑之粉末會導致不同的入射速度與穿透距離，因此藉由控制流量的大小，使得粒子能夠沿著火燄中心移動。以外送粉方式為前提時，粒子受到電漿射流強度的影響，明顯的有被彈開的現象產生，導致粒子呈現分散狀態，在空間分佈範圍廣；內送粉系統則非常集中，呈現橢圓狀的狀態。
最後本研究建立了一基礎的大氣電漿熔射參數對粒子熔融狀態之模擬研究平台，並提供了有助於了解大氣電漿熔射過程之方法。

Air plasma spraying process was wildly used to produce ceramic membranes and thermal barrier coatings in industry field. It has been well-known that the particles melting status and its in-flight velocity was the most important factors that affect the lamellar formation and porosity. The interaction of particles with the plasma jet is crucial to the coating properties. However, direct measurement of particle heating history was difficult in experiments because of its residence time is extremely short. All the information concerning particle melting state can’t thoroughly get from on-line monitor facility. Hence, numerical models have been developed to investigate the in-flight particle melting behavior during spraying process by computational fluid dynamics program FLUENT V6.2©.
The purpose of this study was focus on particles trajectory , heating history as well as its in-flight velocity under various carrier gas flow rate. In this study, the argon plasma jet is simulated. The alumina particle trajectories were tracked in Lagrangian manner.
The results show that the spray-angle will increase as carrier gas flow rate enhance. The phenomenon is more obvious in internal powder injector than external one. As carrier gas flow rate increase , the maxium velocity of plasma jet will lift up and its maxium temperature will decrease.
Particle with internal powder injection has better in-flight velocity and surface temperature than external one. This was due to the location of powder injector. Internal type was much closer to the heating and heart core of plasma jet which resulted in longer heating time and better melting status than external one. The former has higher particle mean surface temperature than latter as we further check particle counts distributions at standoff distance equal to nine centimeter. We use Biot number to analysis the melting state as particle surface temperature reach its melting point and integral mean thermal conductivity was used in this work. The results indicate that there still have fourteen percentage difference between surface temperature and its center point. As far as particle evaporation state be concered, particle residence time was shorter than its evaporation time. It seems like the phenomena wasn’t play an important role in this study.
Furthermore, Particle injection velocity under different carrier gas flow rate resulted from ranges of corresponding particle size and injection location. Particle penetration depth mainly relied on its momentum and particle size. particle injection with external injector will be dispersed by plasma jet because of insufficient in momentum.The dispersion location for internal type was more concentrate than external type.
At last but not least, CFD simulation tool have been developed in this study. It will help us analysis how the process variable affect the coating properties.

目 錄
中文摘要 ………………………………………………………………… Ι
英文摘要 ………………………………………………………………… ΙΙΙ
致謝 ………………………………………………………………… V
目錄 ………………………………………………………………… VΙΙ
圖索引 ………………………………………………………………… IX
表索引 ………………………………………………………………… XII
第一章 緒論................................................................................................. 1
第二章 文獻回顧......................................................................................... 3
2.1 熱熔射技術............................................................................................. 3
2.1.1 熱熔射技術之分類.......................................................................... 3
2.1.2 熱熔射基本原理.............................................................................. 5
2.2 影響熔射主要因素............................................................................... 7
2.2.1 電漿氣體之影響.............................................................................. 9
2.2.2 送粉參數之影響............................................................................ 10
2.2.3 氧化鋁熔融狀態參數之影響....................................................... 12
2.3 粒子在電漿射流之運動分析............................................................... 19
2.4 CFD於大氣電漿熔射之發展與其應用上的限制............................... 21
第三章 理論分析....................................................................................... 31
3.1 模擬系統............................................................................................... 33
3.2 邊界條件............................................................................................... 37
3.2.1 內送粉邊界設定............................................................................ 37
3.2.2 外送粉邊界設定............................................................................ 38
3.3 主控方程式........................................................................................... 40
3.3.1 紊流方程式.................................................................................... 42
VIII
3.3.2 粒子動量方程式............................................................................ 43
3.3.3 粒子熱傳方程式............................................................................ 44
3.4 數值計算............................................................................................... 46
第四章 結果與討論................................................................................... 50
4.1 電漿射流流場之比較........................................................................... 50
4.2 載氣流量對電漿射流之影響............................................................... 57
4.3 載氣流量對粒子之影響....................................................................... 64
4.3.1 粒子飛行速度與表面溫度之比較............................................... 64
4.3.2 載氣流量對粒子受熱過程之影響............................................... 66
4.3.3 載氣流量對粒子運動軌跡之影響............................................... 77
第五章 結論............................................................................................... 82
參考文獻..................................................................................................... 83
中英文對照表............................................................................................. 89
符號說明..................................................................................................... 91
附錄A 主要假設之驗證............................................................................ 94
附錄B 熱輻射現象.................................................................................... 96
自述 ....................................................................................................... 98

圖目錄
第二章
Fig.2-1 Schematic diagram of air plasma spray (Schwenk, 2003). ....................... 7
Fig.2-2 Evaporation constants for various materials in argon plasma as
function of the plasma temperature (Chen and Pfender, 1982). ......................... 15
Fig.2-3 Schematic microstructure of thermal spray coating (Kucuk, 2001)........ 16
Fig.2-4 Structure and thickness of lamellar (Fauchais, 2004). ............................ 16
Fig.2-5 Time range in coating formation (Fauchais, 2004) ................................. 17
Fig.2-6 Different zones in plasma torch (Meillot and Guenadou, 2003)............. 23
第三章
Fig.3-1 CFD simulation flow chart in this study.................................................. 32
Fig.3-2 Equipment facility of the SG-100© plasma spray torch
(Praxair Operation Manual). ............................................................................... 33
Fig.3-3 The geometrical sketch of SG-100© plasma gun. Unit: mm
(Ma, 2005)........................................................................................................... 34
Fig.3-4 Density comparison between FLUENT© 、Chen(1985) and
Boulos(1994)....................................................................................................... 35
Fig.3-5 Computational domain with boundary conditions for internal injection.39
Fig.3-6 Computational domain with boundary conditions for external injection.
.............................................................................................................................. 39
Fig.3-7 Volume meshing (FLUENT user’s guide)............................................... 47
Fig.3-8 Grid structure of the internal powder injection. ...................................... 48
Fig.3-9 Mesh quality of external powder injection.............................................. 48
Fig.3-10 Grid structure of the external powder injection. ................................... 49
Fig.3-11 Mesh quality of external powder injection............................................ 49
第四章
Fig.4-1 3-D computational domains for internal injection (Kang et al., 2006). .. 50
Fig.4-2 Temperature profile comparison between Kang et al.(2006)
and this study....................................................................................................... 52
Fig.4-3 Velocity profile comparison between Kang et al.(2006) and this work. . 52
Fig.4-4 Plasma temperature radial distribution comparison at LStd-off=75mm
between Kang et al.(2006) and this study. .......................................................... 55
X
Fig.4-5 Plasma velocity radial distribution comparison at LStd-off=75mm
between Kang et al.(2006) and this study. .......................................................... 55
Fig.4-6 Contour profile in this study.................................................................... 56
Fig.4-7 Velocity contour profile without particle injection (for case 1). ............. 60
Fig.4-8 Temperature contour profile without particle injection (for case 1). ...... 61
Fig.4-9 Plasma velocity distribution at LStd-off=90mm (for case 1)...................... 62
Fig.4-10 Plasma temperature distribution at LStd-off=90mm (for case1). ............. 62
Fig.4-11 Contour profile without particle injection (for case 2).......................... 63
Fig.4-12 Temperature profile (a)plasma gas (b)In-flight particle surface
temperature comparisons between Ang et al.(2000) and this study.................... 65
Fig.4-13 Velocity profile (a)plasma gas (b)In-flight particle velocity
comparisons between Ang et al.(2000) and this study........................................ 65
Fig.4-14 In-flight particle velocity along the axial direction
with Dp=25μm (for case 1)................................................................................. 67
Fig.4-15 In-flight particle velocity along the axial direction
with Dp=45μm (for case 1)................................................................................. 67
Fig.4-16 In-flight particle heating history along axial direction
with Dp=25μm (for case 1)................................................................................. 68
Fig.4-17 In-flight particle heating history along axial direction
with Dp=45μm (for case 1)................................................................................. 68
Fig.4-18 In-flight particle velocity along the axial direction versus
different type of particle injector for carrier gas flow rate equal to 4SLM
(for case 1 and case2).......................................................................................... 69
Fig.4-19 In-flight particle heating history along the axial direction versus
different type of particle injector for carrier gas flow rate equal to 4SLM
(for case 1 and case2).......................................................................................... 70
Fig.4-20 Particle residence time versus different particle diameter for
various carrier gas flow rate................................................................................ 71
Fig.4-21 Schematic diagram of a particle immersed in argon plasma................. 72
Fig.4-22 Particles surface temperature distribution at LStd-off=90mm
with Dp=25μm (for case 1)................................................................................. 75
Fig.4-23 Particles surface temperature distribution at LStd-off=90mm
with Dp=35μm (for case 1)................................................................................. 75
Fig.4-24 Particles surface temperature distribution at LStd-off=90mm
with Dp=45μm (for case 1)................................................................................. 76
Fig.4-25 The particle average injection velocity various carrier gas flow rate
for different particle diameter (for case 1).......................................................... 77
XI
Fig.4-26 In-flight particle penetration depth along axial direction
with Dp=35μm (for case 1)................................................................................. 78
Fig.4-27 Comparison of particles location at LStd-off=90mm (for case 1). ........... 80
Fig.4-28 Comparison of particles location at LStd-off=90mm (for case 2). ........... 81
附錄B
Fig. B-1 Variation of the reduced time with plasma temperature for an alumina
particle exposed to an argon plasma. (Chen and Pfender, 1982) .......... 96

表目錄
第二章
Table 2-1 Thermal spray technique divided by their energy source and
surrounding atmospheres....................................................................... 5
Table 2-2 Main parameters of plasma spraying process (Vardelle等人, 1982). .... 8
Table 2-3 Results arrangement obtained from literature
(Ang等人, 2001)............................................................................................... 13
Table 2-4 Spread factor models obtained from the literature
(Kang和Hg, 2006). ............................................................................................. 17
Table 2-5 Collection of air plasma spray literature with CFD simulation tool.... 25
第三章
Table 3-1 Physical and thermal properties of aluminaa........................................ 35
Table 3-2 The process variable, diffusion coefficient and source term. .............. 41
Table 3-3 Empirical constant for standard κ-ε model (FLUENT user’s guide)... 42
Table 3-4 Simulation processes of CFD............................................................... 46
Table 3-5 Quality classification based on skewness. ........................................... 47
第四章
Table 4-1 Temperature, T(K) and velocity magnitudes, U(m/s) at monitoring
point ..................................................................................................... 53
Table 4-2 Equation verification by different kinds of plasma gas ....................... 57
Table 4-3 Operation conditions in this study ....................................................... 58

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電漿噴塗裝置操作手冊.
http://www-ferp.ucsd.edu/LIB/PROPS/PANOS/al2o3.html
http://learningcfd.com/