Russian Scientists Develop a Revolutionary Plasma Torch for Restoring Industrial Components
Russian researchers have introduced a breakthrough plasma torch design that could significantly reshape heavy industry by extending the lifespan of critical components while reducing costs and energy consumption
A team from Perm National Research Polytechnic University has unveiled a unique plasma torch architecture that dramatically improves the quality and efficiency of plasma surfacing — a process used to restore and strengthen worn parts in machinery, energy systems, and transportation. The new design has no Russian analogues and directly addresses major drawbacks of existing systems by reducing energy use and ensuring exceptionally high coating quality.
A New Operating Principle
The plasma torch introduces a fundamentally different engineering scheme built around two core components. The central tube simultaneously feeds metallic powder and serves as the first heating element. Through it, a pressurized gas–powder mixture enters the system. Surrounding it, at a distance of just 1–1.5 millimeters, is a ring-shaped nozzle acting as a second heating element. When powered, the two components generate independent plasma arcs that merge into a single high‑energy stream, delivering maximum particle heating. A specially engineered vortex gas flow keeps the powder centered, eliminating wall adhesion and material loss.
Unmatched Technical Performance
The device operates in a current range from 30 to 200 A — twice that of typical systems — making it suitable for both small precision components and large industrial structures. Despite its capability, the voltage remains at just 32–38 V, which is 2.5–3 times lower than comparable solutions, sharply reducing energy consumption.
Testing was conducted on a dedicated robotic stand.
Industrial Impact
For Russian industry, the new plasma torch has enormous potential. Machinery manufacturers can use it to strengthen dies, molds, and cutting tools. In transportation, the technology can extend the life of suspension and transmission components. It is especially valuable for shipbuilding, energy, and the oil and gas sector, where durability and corrosion resistance are critical.
