Investigation of the effects of shear on arc-electrode erosion using a modified arc-electrode mass loss model

The electrodes are the attachment points for an electric arc where electrons and positive ions enter and leave the gas, creating a flow of current. Electrons enter the gas at the cathode and are removed at the anode. Electrons then flow out through the leads on the anode and are replenished from the power supply through the leads on the cathode. Electric arc attachment to the electrode surface causes intensive heating and subsequent melting and vaporization. At that point a multitude of factors can contribute to mass loss, to include vaporization (boiling), material removal via shear forces, chemical reactions, evaporation, and ejection of material in jets due to pressure effects. If these factors were more thoroughly understood and could be modeled, this knowledge would guide the development of an electrode design with minimal erosion. An analytic model was developed by a previous researcher that models mass loss by melting, evaporation and boiling with a moving arc attachment point. This pseudo one-dimensional model includes surface heat flux in periodic cycles of heating and cooling to model motion of a spinning arc in an annular electrode where the arc periodically returns to the same spot. This model, however, does not account for removal of material due to shear or pressure induced effects, or the effects of chemical reactions. As a result of this, the model under-predicts material removal by about 50%. High velocity air flowing over an electrode will result in a shear force which has the potential to remove molten material as the arc melts the surface on its path around the electrode. In order to study the effects of shear on mass loss rate, the model from this previous investigator has been altered to include this mass loss mechanism. The results of this study have shown that shear is a viable mechanism for mass loss in electrodes and can account for the mismatch between theoretical and experimental rates determined by previous investigators. The results of a parametric study of arc attachment factors - including spot size, fall voltage, arc spot rotation rate, ambient bore heat rate, and air mass flow rate - are presented. The parametric study resulted in improving estimates of both the arc spot size and electrode fall voltage, two critical factors affecting electrode heating. Little sensitivity of electrode erosion rate to ambient bore heat rate and rotation rate was found. The erosion rate is found to be sensitive to the mass flow rate of air injected in the arc heater and validation of the model by comparison with more run condition data should be carried out as the data become available.