Thermal plasmas, generated by electric arc discharges, are used in a variety of industrial applications. The electric arc is a constricted electrical discharge with a high temperature in the range 6000-25,000 K. These characteristics are useful in plasma cutting, spraying, welding and specific areas of material processing. The thermal plasma technology is an enabling process technology and its status in the market depends upon its advantages over competing technologies. A few technological challenges to enhance the status of plasma technology are to improve the utilisation of the unique characteristics of the electric arc and to provide enhanced control of the process. In particular, new solutions are required for increasing the plasma-material interaction, controlling the electrode roots and controlling the thermal power generated by the arcing process.
IntroductionA thermal plasma is often considered as a plasma in which local thermodynamic equilibrium (LTE). conditions prevail. Under LTE conditions, the heavy particles in the plasma have approximately the same temperature as the electrons and hence the plasma has a high temperature. This allows the plasma to be used in a number of industrial processes requiring process heat at a high temperature (Pfender 1988). Typical applications of thermal plasmas in industry include joining of metals, plasma cutting, plasma spraying, arc wire spraying, plasma surfacing and material processing.Thermal plasma technology is essentially a process technology that enables the development of an industrial process to manufacture a product that meets market demands. The success of an application of plasma technology in industry will depend upon the technical suitability and advantages the process offers and the cost of the final product.Thermal plasma technology is based on the physical phenomenon of electrical discharges. The basic properties and generic features of the phenomenon create a unique position for the industrial applicability of the process. On the other hand, the limitations and the constraints imposed by the phenomenon on the application process have a strong bearing on the total cost and hence on the acceptance of the process by industry. In this paper, the advantages of plasma technology, its phenomenal constraints and future challenges for technology developments are highlighted.