High-speed imaging investigation of transient phenomena impacting plasma arc cutting process optimization

In this work, we report on the investigation of selected transient phenomena taking place in plasma arc cutting (PAC) that are relevant for process optimization. High-speed imaging diagnostics is exploited for the characterization of different technological solutions in order to provide deeper insights into torch and process design. In particular, the pilot arc start-up phase is analysed for a 250A automatic dual-gas torch equipped with electrodes with different shapes of the initial insert recess, revealing that there is no influence of the recess depth on the time for the stabilization of the pilot arc attachment on the cathode insert. The influence of different insert materials, including Ag-Hf and Cu-Zr binary alloys, on erosion during the shut-down phase is investigated at 120A and reduced emission of material and faster shut-down is found for alloy inserts compared with standard Hf inserts. The start-up and shut-down transients are also investigated during transferred arc operation using a modified nozzle that comprises a viewing port on one side of the nozzle, and pulsing arc behaviour inside the plasma chamber that is correlated with cathode-nozzle voltage oscillations at a frequency of 7.7 kHz is found. Finally, results regarding the influence of different plasma gas diffusers on the arc stability during the cutting initiation phase in a 100A mono-gas manual torch are reported.