Unique erosion features of hafnium cathode in atmospheric pressure arcs of air, nitrogen and oxygen

Experimental investigation of cathode erosion in atmospheric pressure hafnium-electrode plasma torches is reported under different plasma environments along with the results of numerical simulation. Air, nitrogen and oxygen are the plasma gases considered. Distinct differences in the erosion features in different plasmas are brought out. Cathode images exhibiting a degree of erosion and measured erosion rates are presented in detail as a function of time of arc operation and arc current. Physical erosion rates are determined using high precision balance. The changes in the surface microstructures are investigated through scanning electron microscopy (SEM). Evolution of cathode chemistry is determined using energy dispersive x-ray spectroscopy (EDX). Numerical simulation with proper consideration of the plasma effects is performed for all the plasma gases. The important role of electromagnetic body forces in shaping the flow field and the distribution of pressure in the region is explored. It is shown that the mutual interaction between fluid dynamic and electromagnetic body forces may self-consistently evolve a situation of an extremely low cathode erosion rate. (paper)