Computational Analysis of Flow Separation in Non-Transferred Plasma Torch: Causes, Impacts and Control Methods

In a non-transferred plasma torch, the working gas becomes ionized and forms plasma as it interacts with the electric arc at the cathode tip. However, in certain cathode shapes, particularly flat ones, and under specific conditions, the gas flow can separate at the cathode tip, forming a vortex region. While this flow separation is influenced by geometric factors, it occurs in the critical zone where plasma is generated. Understanding the causes of this separation is essential, as it may significantly impact torch performance. If the separation proves detrimental, it is important to identify ways to mitigate it. This paper presents a computational analysis of a non-transferred plasma torch to investigate the physics behind flow separation. The results highlight the location and causes of the separation, as well as its potential advantages and disadvantages. Finally, the paper explores theoretical approaches to address flow separation in plasma torches, offering practical insights for enhancing their design and efficiency.