2014, Toropchin, A., Frolov, V., Pipa, A.V., Kozakov, R., Uhrlandt, D.

Magneto-hydrodynamic simulations of the arc and fluid simulations of the weld pool can be beneficial in the analysis and further development of arc welding processes and welding machines. However, the appropriate coupling of arc and weld pool simulations needs further improvement. The tungsten inert gas (TIG) welding process is investigated by simulations including the weld pool. Experiments with optical diagnostics are used for the validation. A coupled computational model of the arc and the weld pool is developed using the software ANSYS CFX. The weld pool model considers the forces acting on the motion of the melt inside and on the surface of the pool, such as Marangoni, drag, electromagnetic forces and buoyancy. The experimental work includes analysis of cross-sections of the workpieces, highspeed video images and spectroscopic measurements. Experiments and calculations have been performed for various currents, distances between electrode and workpiece and nozzle diameters. The studies show the significant impact of material properties like surface tension dependence on temperature as well as of the arc structure on the weld pool behaviour and finally the weld seam depth. The experimental weld pool profiles and plasma temperatures are in good agreement with computational results.

2014, Uhrlandt, D., Baeva, M., Pipa, A.V., Kozakov, R., Gött, G.

This work presents modelling results concerning a tungsten inert gas (TIG) welding arc. The model provides a consistent description of the free burning arc, the arc attachment and the electrodes. Thermal and chemical non-equilibrium is considered in the whole arc area, and a detailed model of the cathode space-charge sheath is included. The mechanisms in the cathode pre-sheath are treated in the framework of a non-equilibrium approach which is based on a two-fluid description of electrons and heavy particles and a simplified plasma chemistry of argon. A consistent determination of the electrode fall voltages and temperature distributions is achieved. The model is applied to arcs in pure argon at currents up to 250 A, whereby welding of a workpiece made of mild steel with a fixed burner is considered. Arc voltages in the range from 12 to 17 V are obtained at 50 at 250 A, respectively. The space-charge sheath voltage is found to be about 7 V and almost independent of the current. The corresponding temperatures of the cathode tip are in the range from 3,000 K to about 3,800 K. The results obtained are in a good agreement with measurements.

2020, Hink, R., Pipa, A.V., Schäfer, J., Caspari, R., Weichwald, R., Foest, R., Brandenburg, R.

Surface dielectric barrier discharges are investigated in order to explore the combined effects of barrier thickness and microstructure of the exposed electrode on the ion wind generation. Actuators with straight and structured high voltage electrodes with characteristic sizes of 200 and 250 µm and dielectric thicknesses of 0.5, 1 and 2 mm are compared. It is observed that: i) actuator efficiency of ion wind generation strongly depends on the applied voltage amplitude; ii) operation voltage depends on the dielectric thickness logarithmically; iii) electrode microstructure slightly increases the dynamic pressure (few percent in maximum), however the effect decreases with thicker dielectrics and smaller electrode structures; iv) the pattern of the most intensive discharge parts as well as the dielectric erosion repeats the regular structure of the electrodes down to 200 µm. Several identical samples are tested during different days to estimate the impact of the air humidity and the degradation of the dielectric. The microscale precision of the sample manufacture was accomplished by a commercial facility for printed circuit boards. © 2020 The Author(s). Published by IOP Publishing Ltd.

2020, Puth, A., Kusýn, L., Pipa, A.V., Burlacov, I., Dalke, A., Hamann, S., van Helden, J.H., Biermann, H., Röpke, J.

The active screen plasma nitrocarburizing technology is an improvement of conventional plasma nitrocarburizing by providing a homogeneous temperature distribution within the workload and reducing soot formation. In this study, an industrial-scale active screen (AS) made of carbon-fibre-reinforced carbon serves as the cathode as well as the carbon source for the plasma-chemical processes taking place. The pulsed dc discharge was maintained at a few mbar of pressure while simultaneously being fed with a mixed gas flow of hydrogen and nitrogen ranging from 10 to 100 slh. Using in situ infrared laser absorption spectroscopy with lead salt tuneable diode lasers and external-cavity quantum cascade lasers, the temperatures and concentrations of HCN, NH3, CH4, C2H2, and CO have been monitored as a function of pressure and total gas flow. To simulate industrial treatment conditions the temperature of the sample workload in the centre of the reactor volume was kept at 773 K by varying the plasma power at the AS between 6 and 8.5 kW. The resulting spectroscopically measured temperatures in the plasma agreed well with this value. Concentrations of the various species ranged from 6 × 1013 to 1 × 1016 cm−3 with HCN being the most abundant species.