气体放电导入电流的丝电爆制备纳米粉方法研究
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摘要
纳米金属粉在许多方面具有独特的优异性能，在国民经济和国防各领域都具有广阔的应用前景。但目前纳米金属粉的应用领域却十分有限，其原因主要是纳米粉价格昂贵，缺乏工业级宏量化可控制备技术。丝电爆技术用于纳米粉制备时具有许多优势，被认为是一种适合工业化规模生产纳米粉的方法。已有的丝电爆方法都是首先将金属丝与电极可靠接触，然后施加脉冲高电压，大电流通过接触的方式从电极导入到金属丝而发生电爆。但这种接触式丝电爆方法存在设备故障率高、烧损电极、粉末中始终存在微米级大颗粒等许多问题，而这些问题的产生几乎都与接触导入电流方式有关。为此本文提出了利用气体放电导入电流的丝电爆新方法，并对其进行了系统研究。
为了实现通过气体放电导入电流，建立了两种气体放电式丝电爆方法，即孔-板电极式丝电爆方法和圆锥电极式丝电爆方法，并对这两种方法的气隙击穿特性进行了研究。在孔-板电极式丝电爆过程中，存在单气隙放电和双气隙放电两种气体放电模式，单气隙放电的击穿电压比双气隙放电的击穿电压小。能够发生双气隙放电时对应金属丝的最小长度，为适合丝电爆发生的最佳长度。在圆锥电极式丝电爆过程中，只存在双气隙放电模式，更便于工程应用。丝端部与电极之间的气隙放电过程与尖-板电极间气体放电过程相似：随着初始充电电压的增加，击穿气隙会逐渐增大，气隙的平均击穿场强随之减小。气隙的击穿电压与电极间距有关，电极间距增大后，气隙的击穿电压随之增大。
丝电爆过程中，电流可以通过接触和气体放电两种方式导入到金属丝上，通过实验结果认识电流的导入机制。这两种方式导入电流时，光测量装置检测到的丝端部光电流都几乎与回路放电电流同时产生，而中间位置的光电流则要滞后一段时间；由探针收集的产物可知，金属丝端部主要形成金属熔融粒子，丝中间部分主要形成金属蒸汽；通过气体放电方式导入电流时，电极烧损明显减轻，并可以避免“积瘤”产生。分析可知，接触方式导入电流时丝端部也存在气体放电现象，大电流主要通过气体放电形成的等离子体导入。等离子体对电流的旁路作用会阻碍能量向金属丝沉积，这是产生微米级大颗粒和“积瘤”主要原因。
进行丝电爆制备纳米粉实验，利用探针直接采集金属丝各部分形成的粉末，确定微米级大颗粒的形成位置，认识微米级大颗粒的形成特征。在丝端部形成的粉末中，微米级大颗粒比例要比丝中间部分的比例大。这种现象的原因是能量向丝中间部分和丝端部沉积的方式不同。在丝中间部分，能量主要通过焦耳加热作用沉积，而在丝端部，还会受到等离子体中高温带电粒子的高速撞击作用，这也会向丝端部沉积一部分能量。实验还发现，初始电压过高时粉末中微米级大颗粒的比例也会较大，其原因是丝表面发生了沿面放电现象，形成的等离子体湮没整根金属丝。等离子体对电流的旁路作用使丝上的沉积能量减小，因此粉末中微米级大颗粒比例也明显较大。最适合制备纳米粉的初始电压，为金属丝表面不发生沿面放电时对应的最高电压。进一步分析可知，丝表面沿面放电现象发生的平均击穿场强约为2.37kV/cm。丝表面不发生沿面放电时，沉积在丝上的能量密度随初始线能量的增加而增大，发生沿面放电后，能量密度就会迅速减小。
建立了丝表面气体层模型，对气体放电式丝电爆过程进行电路模拟，认识能量沉积特征及其与工艺参数的关系。该模型考虑到了沿面放电现象对金属丝上沉积能量的影响，更接近丝电爆现象的实际情况。结果表明，丝端部放电气隙δ对气体放电式丝电爆过程影响很小；减小放电回路电感可明显提高能量沉积速率；在保持电容器储能不变的情况下，通过提高初始电压和减小电容的方法可以提高能量沉积速率；通过合理匹配金属丝直径和长度能够使爆炸前在金属丝上沉积足够的能量。
在以上对气体放电式丝电爆方法研究的基础上，开发了一套实验室规模的气体放电式丝电爆制备纳米粉设备，该设备适合的金属丝直径范围为0.05~0.8mm，金属丝长度范围为25~100mm，爆炸频率可达2.1HZ以上，送丝率可达105mm/s以上。本设备在适用的丝径范围和生产效率方面优于国内外已有的电爆设备。
Metal nanopowders are materials with manifold excellent properties and havebroad application prospects in the field of national economy and national defence.However, the applications of metal nanopowders are limited at present because oftheir high price and the lack of preparation technology. Wire Electrical Explosion(WEE) method has many advantages in nanopowders preparation, and is considered asa preparation method for large-scale industrial nanopowders. In present WEE method,a metal wire was first linked with two electrodes, then the current was injected intothe metal wire from the electrodes through the channels which were provided by the"contact" of the electrodes and the wire ends. This method has lots of unavoidablydisadvantages in practice application, such as the high fault rate, the electrodesbeing ablated easily, some micron-size particles remaining in the powders, and so on.Previous studies shows that all of those problems are relevant to the "contact"channels through which the current is injected into the metal wire from the electrodes.Hence, a new method of WEE with gas discharge is proposed in this paper, in whichthe current flows into the wire by gas discharge. Then this WEE by gas discharge isalso investigated systematically.
For the current channelling into the wire by gas discharge, two methods of WEEby gas discharge devices are designed, which are hole-to-plane electrode WEE deviceand conical electrode WEE device respectively. And the breakdown properties of theabove two methods are also researched. In the process of hole-to-plane electrode WEE,there are two forms of gas discharge, including the single air-gap discharge and thedouble air-gap discharge. The breakdown voltage of the single air-gap discharge issmaller than that of the double air-gap discharge. The optimum length of the metalwire for electrical explosion is the minimum length when the double air-gap dischargecan occur. However, there is only single air-gap discharge exist in the process ofconical electrode WEE. Hence, the conical electrode WEE is beneficial forengineering application. The gap discharge in this method is similar to that in therod-plane air gap: With the increasing of initial charging voltage, the length of theair-gap increases and the average breakdown electric field strength decreases; Thebreakdown voltage of air-gap is depedent on the distance between two electrodes, andgap increases with the increasing of electrodes distance.
In the process of WEE, the current can be injected into the metal wire through the channels which are provided by the "contact" of the electrodes and the wire ends,as well as the "gas discharge" between them. Mechanism of current injection isdeduced according to the experimental results. In these two channels, the photocurrentdetected by photodiodes at the wire ends almost occurs simultaneously with thecircuit discharge current, but that at the center section lags behind the circuitdischarge current obviously; The initial explosion products of the wire ends is liquid,and that of the other parts of wire is gas; When the current is injected by the way ofthe "breakdown", the electrodes ablated is slight obviously, and there is no remainderon the electrodes. These results indicates that gas discharge also occurs at the wireends when the current is injected by the way of "contact". Because the plasmaprovides an alternated current path, the energy density of the wire ends decreases.Hence, the wire ends couldn't explode and formed remainder on the electrodes.
In the process of nanopowders preparation by gas discharge WEE, the powdersfrom wire various sections are collected by a quartz probe, then the position ofmicron-size particles are observed. Moreover, the characters of particle formation arealso analyzed. The results shows that, the micron-size particles proportion of the wireends powders is higher than that of wire center section powders. The main reason forthis phenomenon is that the ways of energy deposition are different. At the center ofthe wire, the energy would deposit into the wire mainly by the Joule Heating.However, at the ends of wire, the charged particles which came from the plasmawould strike on the wire surface at a high speed. Thus, some energies also could beinjected into the wire end by this effect besides of the Joule Heating. When thecharging voltage is too high, the breakdown which is the major reason of theincreasing of micron-size particles proportion will occur surrounding the wire surface,and the plasma which is known as the shunting arc will form by the gas discharge.The optimum charging voltage for nanopowders preparation is the maximum voltageat which the surface discharge could not occur. The above analysis indicates that theaverage breakdown electric field strength for surface discharge is about2.37kV/cm,and the energy density deposition in the wire increases with the increasing of initiallinear energy, However, it will decrease again when the surface discharge occurred.
Based on the experimental results, a gaseous layer model which considers the gasdischarge along the wire surface is proposed to understanding the characters of energydeposition and the influence of technological parameters. The electrical behavior ofthe discharge gap WEE is studied by numerically solving nonlinear differentialequation describing the discharge circuit based on this model. The numerical simulation results also shows that, the discharged gap has a little influence on theprocess of WEE. The energy deposition rate increases with the dcreasing of the circuitinductance or the capacitance of the energy-storage capacitor when the storage energyremains constant. Enough energy could deposit into the wire before the explosionwith the rational matching of the wire length and wire diameter.
Based on the above research results, a industrialized equipment of gas dischargeWEE in laboratory scale is developed. In this equipment, the range of the wirediameter and length are0.05~0.8mm and25~100mm, respectively. Moreover, theexplosion frequency is higher than2.1Hz and the efficiency of wire feed is more than105mm/s. This gas discharge WEE equipment is better than the other equipments onthe respect of the wire diameter range the and production efficiency.
为了实现通过气体放电导入电流，建立了两种气体放电式丝电爆方法，即孔-板电极式丝电爆方法和圆锥电极式丝电爆方法，并对这两种方法的气隙击穿特性进行了研究。在孔-板电极式丝电爆过程中，存在单气隙放电和双气隙放电两种气体放电模式，单气隙放电的击穿电压比双气隙放电的击穿电压小。能够发生双气隙放电时对应金属丝的最小长度，为适合丝电爆发生的最佳长度。在圆锥电极式丝电爆过程中，只存在双气隙放电模式，更便于工程应用。丝端部与电极之间的气隙放电过程与尖-板电极间气体放电过程相似：随着初始充电电压的增加，击穿气隙会逐渐增大，气隙的平均击穿场强随之减小。气隙的击穿电压与电极间距有关，电极间距增大后，气隙的击穿电压随之增大。
丝电爆过程中，电流可以通过接触和气体放电两种方式导入到金属丝上，通过实验结果认识电流的导入机制。这两种方式导入电流时，光测量装置检测到的丝端部光电流都几乎与回路放电电流同时产生，而中间位置的光电流则要滞后一段时间；由探针收集的产物可知，金属丝端部主要形成金属熔融粒子，丝中间部分主要形成金属蒸汽；通过气体放电方式导入电流时，电极烧损明显减轻，并可以避免“积瘤”产生。分析可知，接触方式导入电流时丝端部也存在气体放电现象，大电流主要通过气体放电形成的等离子体导入。等离子体对电流的旁路作用会阻碍能量向金属丝沉积，这是产生微米级大颗粒和“积瘤”主要原因。
进行丝电爆制备纳米粉实验，利用探针直接采集金属丝各部分形成的粉末，确定微米级大颗粒的形成位置，认识微米级大颗粒的形成特征。在丝端部形成的粉末中，微米级大颗粒比例要比丝中间部分的比例大。这种现象的原因是能量向丝中间部分和丝端部沉积的方式不同。在丝中间部分，能量主要通过焦耳加热作用沉积，而在丝端部，还会受到等离子体中高温带电粒子的高速撞击作用，这也会向丝端部沉积一部分能量。实验还发现，初始电压过高时粉末中微米级大颗粒的比例也会较大，其原因是丝表面发生了沿面放电现象，形成的等离子体湮没整根金属丝。等离子体对电流的旁路作用使丝上的沉积能量减小，因此粉末中微米级大颗粒比例也明显较大。最适合制备纳米粉的初始电压，为金属丝表面不发生沿面放电时对应的最高电压。进一步分析可知，丝表面沿面放电现象发生的平均击穿场强约为2.37kV/cm。丝表面不发生沿面放电时，沉积在丝上的能量密度随初始线能量的增加而增大，发生沿面放电后，能量密度就会迅速减小。
建立了丝表面气体层模型，对气体放电式丝电爆过程进行电路模拟，认识能量沉积特征及其与工艺参数的关系。该模型考虑到了沿面放电现象对金属丝上沉积能量的影响，更接近丝电爆现象的实际情况。结果表明，丝端部放电气隙δ对气体放电式丝电爆过程影响很小；减小放电回路电感可明显提高能量沉积速率；在保持电容器储能不变的情况下，通过提高初始电压和减小电容的方法可以提高能量沉积速率；通过合理匹配金属丝直径和长度能够使爆炸前在金属丝上沉积足够的能量。
在以上对气体放电式丝电爆方法研究的基础上，开发了一套实验室规模的气体放电式丝电爆制备纳米粉设备，该设备适合的金属丝直径范围为0.05~0.8mm，金属丝长度范围为25~100mm，爆炸频率可达2.1HZ以上，送丝率可达105mm/s以上。本设备在适用的丝径范围和生产效率方面优于国内外已有的电爆设备。
Metal nanopowders are materials with manifold excellent properties and havebroad application prospects in the field of national economy and national defence.However, the applications of metal nanopowders are limited at present because oftheir high price and the lack of preparation technology. Wire Electrical Explosion(WEE) method has many advantages in nanopowders preparation, and is considered asa preparation method for large-scale industrial nanopowders. In present WEE method,a metal wire was first linked with two electrodes, then the current was injected intothe metal wire from the electrodes through the channels which were provided by the"contact" of the electrodes and the wire ends. This method has lots of unavoidablydisadvantages in practice application, such as the high fault rate, the electrodesbeing ablated easily, some micron-size particles remaining in the powders, and so on.Previous studies shows that all of those problems are relevant to the "contact"channels through which the current is injected into the metal wire from the electrodes.Hence, a new method of WEE with gas discharge is proposed in this paper, in whichthe current flows into the wire by gas discharge. Then this WEE by gas discharge isalso investigated systematically.
For the current channelling into the wire by gas discharge, two methods of WEEby gas discharge devices are designed, which are hole-to-plane electrode WEE deviceand conical electrode WEE device respectively. And the breakdown properties of theabove two methods are also researched. In the process of hole-to-plane electrode WEE,there are two forms of gas discharge, including the single air-gap discharge and thedouble air-gap discharge. The breakdown voltage of the single air-gap discharge issmaller than that of the double air-gap discharge. The optimum length of the metalwire for electrical explosion is the minimum length when the double air-gap dischargecan occur. However, there is only single air-gap discharge exist in the process ofconical electrode WEE. Hence, the conical electrode WEE is beneficial forengineering application. The gap discharge in this method is similar to that in therod-plane air gap: With the increasing of initial charging voltage, the length of theair-gap increases and the average breakdown electric field strength decreases; Thebreakdown voltage of air-gap is depedent on the distance between two electrodes, andgap increases with the increasing of electrodes distance.
In the process of WEE, the current can be injected into the metal wire through the channels which are provided by the "contact" of the electrodes and the wire ends,as well as the "gas discharge" between them. Mechanism of current injection isdeduced according to the experimental results. In these two channels, the photocurrentdetected by photodiodes at the wire ends almost occurs simultaneously with thecircuit discharge current, but that at the center section lags behind the circuitdischarge current obviously; The initial explosion products of the wire ends is liquid,and that of the other parts of wire is gas; When the current is injected by the way ofthe "breakdown", the electrodes ablated is slight obviously, and there is no remainderon the electrodes. These results indicates that gas discharge also occurs at the wireends when the current is injected by the way of "contact". Because the plasmaprovides an alternated current path, the energy density of the wire ends decreases.Hence, the wire ends couldn't explode and formed remainder on the electrodes.
In the process of nanopowders preparation by gas discharge WEE, the powdersfrom wire various sections are collected by a quartz probe, then the position ofmicron-size particles are observed. Moreover, the characters of particle formation arealso analyzed. The results shows that, the micron-size particles proportion of the wireends powders is higher than that of wire center section powders. The main reason forthis phenomenon is that the ways of energy deposition are different. At the center ofthe wire, the energy would deposit into the wire mainly by the Joule Heating.However, at the ends of wire, the charged particles which came from the plasmawould strike on the wire surface at a high speed. Thus, some energies also could beinjected into the wire end by this effect besides of the Joule Heating. When thecharging voltage is too high, the breakdown which is the major reason of theincreasing of micron-size particles proportion will occur surrounding the wire surface,and the plasma which is known as the shunting arc will form by the gas discharge.The optimum charging voltage for nanopowders preparation is the maximum voltageat which the surface discharge could not occur. The above analysis indicates that theaverage breakdown electric field strength for surface discharge is about2.37kV/cm,and the energy density deposition in the wire increases with the increasing of initiallinear energy, However, it will decrease again when the surface discharge occurred.
Based on the experimental results, a gaseous layer model which considers the gasdischarge along the wire surface is proposed to understanding the characters of energydeposition and the influence of technological parameters. The electrical behavior ofthe discharge gap WEE is studied by numerically solving nonlinear differentialequation describing the discharge circuit based on this model. The numerical simulation results also shows that, the discharged gap has a little influence on theprocess of WEE. The energy deposition rate increases with the dcreasing of the circuitinductance or the capacitance of the energy-storage capacitor when the storage energyremains constant. Enough energy could deposit into the wire before the explosionwith the rational matching of the wire length and wire diameter.
Based on the above research results, a industrialized equipment of gas dischargeWEE in laboratory scale is developed. In this equipment, the range of the wirediameter and length are0.05~0.8mm and25~100mm, respectively. Moreover, theexplosion frequency is higher than2.1Hz and the efficiency of wire feed is more than105mm/s. This gas discharge WEE equipment is better than the other equipments onthe respect of the wire diameter range the and production efficiency.
引文
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