Systems, devices, and methods generating a plasma flow are disclosed. A method may include applying energy that alternates between being at a base level for a first duration and at a pulse level for a second duration according to a controlled pattern, generating a plasma flow having a directional axis, and discharging the plasma flow alternating between a base configuration and a pulse configuration according to the controlled pattern. The plasma flow in the base configuration may have (1) a first temperature at the outlet and (2) a first flow front that advances along the directional axis. The plasma flow in the pulse configuration may have (1) a second temperature at the outlet that is greater than the first temperature and (2) a second flow front that advances along the directional axis at a speed greater than the first flow front.

A consumable for a torch head is disclosed. The consumable for a torch head includes a frustoconical operative end, and a concave outer surface formed on the frustoconical operative end. The concave outer surface is configured to guide a flow of gas to a focal point downstream of the frustoconical operative end.

A plasma torch has a torch body provided with a plurality of stacked torch body segments disposed between a rear electrode unit and a front electrode unit. The torch body forms a circular channel through which gas flows in an axial direction. Each torch body segment has a circular disc shape in which a central circular through-hole is formed to form the channel. Each segment includes gas supply ports defining a spiral-shaped flow path along the through hole on a first side of the segment so as to introduce a reactive gas, a cooling flow path, a cooling water supply flow path, a cooling water discharge flow path, a gas supply flow path, a gas branch flow path, a cooling water supply branch flow path, and a cooling water discharge branch flow path.

An atomic beam generator includes a cathode constituted as a housing having an emission surface provided with an irradiation port through which an atomic beam is emissive; an anode disposed inside the cathode to generate plasma between the cathode and the anode; and a magnetic field generating unit including a first magnetic field generating unit that generates a first magnetic field and a second magnetic field generating unit that generates a second magnetic field, and guiding positive ions produced in the cathode to the emission surface by generating, in the cathode, the first magnetic field and the second magnetic field both parallel to the emission surface such that a magnetic field direction is leftward in the first magnetic field and is rightward in the second magnetic field when viewed from an emission surface side on condition of the first magnetic field being positioned above the second magnetic field.

A plasma spraying device includes a torch head which has a plasma channel that extends between a cathode and an anode. The plasma channel is bounded by a plurality of neutrodes which are electrically insulated from each other. A gap extends between the frontmost neutrode and the anode, which gap is divided into at least two sections. There is a radial distance and an axial distance between the two sections. An insulating disk is arranged in each of the two sections.

Vacuum plasma gun and method of controlling plasma arc in a vacuum plasma gun. Vacuum plasma gun includes a rear gun body section having an electrode, and a cascade section configured to connect to the rear gun body section. The cascade section includes a plurality of neutrodes arranged to form a neutrode stack. The method includes connecting a cascade neutrode stack to a rear body section of a vacuum plasma gun.

An atomic beam generator includes a cathode constituted as a housing having an emission surface provided with an irradiation port through which an atomic beam is emissive; an anode disposed inside the cathode to generate plasma between the cathode and the anode; and a magnetic field generating unit including a first magnetic field generating unit that generates a first magnetic field and a second magnetic field generating unit that generates a second magnetic field, and guiding positive ions produced in the cathode to the emission surface by generating, in the cathode, the first magnetic field and the second magnetic field both parallel to the emission surface such that a magnetic field direction is leftward in the first magnetic field and is rightward in the second magnetic field when viewed from an emission surface side on condition of the first magnetic field being positioned above the second magnetic field.

A plasma torch has a multi-electrode front electrode and a button-type rear electrode. The plasma torch allows initial discharge to be easily performed by using the button-type rear electrode and an auxiliary electrode for discharge. Initial ignition of a high-output arc plasma torch is performed easily by naturally forming an arc column between the rear electrode and the front electrode, even in the absence of efficient discharge between the rear electrode and the auxiliary electrode for initial discharge.

The design and implementation of a thermally optimized neutrode stack for cascaded plasma guns is provided that reduces the thermal loss to the water while minimizing peak stack temperatures. Optimizing the cooling will permit longer stacks to be used without the penalty of high thermal losses.

The present invention is directed at a plasma torch and methods of plasma spraying wherein the delivery of plasma and spray material occurs at extended locations from the anode arc root attachment. Relatively high specific power and relatively high enthalpy plasmas are employed along with a plasma extension module to deliver a plasma spray at a remote location with a minimum enthalpy value.