Mastering thermal power equal to that of the surface of the sun in a highly purified and controlled environment; these are our strengths and commitments day after day, year after year.
For most people, surrounding matter in everyday life is composed of solids, liquids, or gases. But there is a fourth state of matter: plasma. Plasma may be less known, but it is observed on a regular basis without even realizing it. Lightning, electric sparks, fluorescent and Northern lights, as well as starlight, are all manifestations of matter in the plasma state. As much as 99.99% of the visible universe is plasma. Plasma is an ionized gas, which means that sufficient energy is provided to free electrons from atoms or molecules and to allow both species – ions and free electrons – to coexist. This electron “sea” allows matter in the plasma state to conduct electricity, somewhat like a conductive metal. This is one of the properties that makes plasma so radically different from their gaseous counterpart. Plasma can reach temperatures of about 10 000 °C, equal to the temperature at the surface of the sun, and way beyond the hottest flame resulting from fuel combustion, which burns at approximately 3 000 °C. Artificial plasma can be generated in several different ways but based on a common principle: there must be energy input to produce and sustain it.
Tekna was founded in 1990 to commercialize a patented inductively coupled plasma (ICP) torch technology developed by Professors Maher Boulos and Jerzy Jurewicz at University of Sherbrooke.
Their new ICP torch design featured a robust ceramic plasma confinement tube, surrounded by a high-velocity water film cooling that protects the tube from the high-energy fluxes emitted by the plasma. A gas distribution head was mounted on top of the polymer-based torch body which houses the coaxial induction coil, and a water-cooled nozzle was mounted at the exit of the torch. A specifically engineered gas flow pattern in the confinement tube creates a virtual boundary the plasma cannot cross; this is what prevents the plasma from contacting the real walls and maintains the integrity of the torch components. The basic concept of ICP torches manufactured by Tekna today remains essentially unchanged, but improvements in torch design were made to achieve energy efficiency that meets industrial scale operation requirements, and to adapt it to specific applications.
Tekna was founded in 1990 to commercialize a patented inductively coupled plasma (ICP) torch technology developed by Professors Maher Boulos and Jerzy Jurewicz at University of Sherbrooke.
Their new ICP torch design featured a robust ceramic plasma confinement tube, surrounded by a high-velocity water film cooling that protects the tube from the high-energy fluxes emitted by the plasma. A gas distribution head was mounted on top of the polymer-based torch body which houses the coaxial induction coil, and a water-cooled nozzle was mounted at the exit of the torch. A specifically engineered gas flow pattern in the confinement tube creates a virtual boundary the plasma cannot cross; this is what prevents the plasma from contacting the real walls and maintains the integrity of the torch components. The basic concept of ICP torches manufactured by Tekna today remains essentially unchanged, but improvements in torch design were made to achieve energy efficiency that meets industrial scale operation requirements, and to adapt it to specific applications.
In Tekna’s ICP technology, the plasma is generated by transferring electrical energy from the induction coil to the gas flowing through a confinement tube, where the plasma discharge occurs.
The radiofrequency current in the coil creates an alternating magnetic field, which in turn induces an annular electric field inside the discharge region. It is this induced electric field that drives ohmic heating of the gas, sustaining a stable plasma discharge. Depending on plasma operating conditions, the local temperature at the core of the discharge, which can easily reach 10 000 o C, is more than necessary to melt and evaporate any materials known to Man.
In Tekna’s ICP technology, the plasma is generated by transferring electrical energy from the induction coil to the gas flowing through a confinement tube, where the plasma discharge occurs. The radiofrequency current in the coil creates an alternating magnetic field, which in turn induces an annular electric field inside the discharge region. It is this induced electric field that drives ohmic heating of the gas, sustaining a stable plasma discharge. Depending on plasma operating conditions, the local temperature at the core of the discharge, which can easily reach 10 000 o C, is more than necessary to melt and evaporate any materials known to Man.
In Tekna’s ICP technology, the plasma is generated by transferring electrical energy from the induction coil to the gas flowing through a confinement tube, where the plasma discharge occurs.
The radiofrequency current in the coil creates an alternating magnetic field, which in turn induces an annular electric field inside the discharge region. It is this induced electric field that drives ohmic heating of the gas, sustaining a stable plasma discharge. Depending on plasma operating conditions, the local temperature at the core of the discharge, which can easily reach 10 000 o C, is more than necessary to melt and evaporate any materials known to Man.
In Tekna’s ICP technology, the plasma is generated by transferring electrical energy from the induction coil to the gas flowing through a confinement tube, where the plasma discharge occurs. The radiofrequency current in the coil creates an alternating magnetic field, which in turn induces an annular electric field inside the discharge region. It is this induced electric field that drives ohmic heating of the gas, sustaining a stable plasma discharge. Depending on plasma operating conditions, the local temperature at the core of the discharge, which can easily reach 10 000 o C, is more than necessary to melt and evaporate any materials known to Man.
Tekna’s core technology—inductively coupled plasma—is used across four key applications. These include the production of metal nanoparticles and micron-sized metal powders, as well as supporting hypersonic materials testing in wind tunnel environments. Details on how plasma is applied and the products it enables are presented below.
The plasma synthesis of nanopowders relies on a precursor — generally a fine powder, although liquids or gases may also be employed depending on the target material — that is injected into the core of the plasma discharge through a water-cooled probe.
The precursor feed rate is carefully controlled to ensure sufficient energy transfer from the plasma to raise the material temperature above its boiling point, resulting in complete vaporization. The generated vapor cloud is then conveyed downstream to a quenching zone, where exposure to high gas flow rates produces a rapid local temperature drop. This rapid cooling initiates in-flight nucleation and condensation, leading to the formation of nanoparticles.
By adjusting the quench conditions, the resulting particle size can be tailored, with typical mean diameters ranging from approximately 50 to few hundred nanometers.
The plasma synthesis of nanopowders relies on a precursor — generally a fine powder, although liquids or gases may also be employed depending on the target material — that is injected into the core of the plasma discharge through a water-cooled probe.
The precursor feed rate is carefully controlled to ensure sufficient energy transfer from the plasma to raise the material temperature above its boiling point, resulting in complete vaporization. The generated vapor cloud is then conveyed downstream to a quenching zone, where exposure to high gas flow rates produces a rapid local temperature drop. This rapid cooling initiates in-flight nucleation and condensation, leading to the formation of nanoparticles.
By adjusting the quench conditions, the resulting particle size can be tailored, with typical mean diameters ranging from approximately 50 to few hundred nanometers.
Plasma spheroidization of powders requires a feedstock — typically a rather fine powder — that is injected into the center of the plasma discharge through a water-cooled probe.
The powder feed rate is adjusted to ensure sufficient energy transfer from the plasma to raise the material temperature slightly above its melting point, resulting in complete melting of the particles while minimizing overheating. Upon exiting the plasma torch, the molten droplets freely fall, and surface tension reshape them into spherical particles. This morphology is preserved during subsequent solidification. As the process does not involve material shearing by a gas stream, the resulting spheroidized particles exhibit a highly spherical shape and an exceptionally smooth surface. In addition, plasma spheroidization offers high process yields (routinely exceeding 90%), as the particle size distribution of the product is defined upstream by appropriate sieving of the feedstock, thereby maximizing material utilization.
Plasma spheroidization of powders requires a feedstock — typically a rather fine powder — that is injected into the center of the plasma discharge through a water-cooled probe.
The powder feed rate is adjusted to ensure sufficient energy transfer from the plasma to raise the material temperature slightly above its melting point, resulting in complete melting of the particles while minimizing overheating. Upon exiting the plasma torch, the molten droplets freely fall, and surface tension reshape them into spherical particles. This morphology is preserved during subsequent solidification. As the process does not involve material shearing by a gas stream, the resulting spheroidized particles exhibit a highly spherical shape and an exceptionally smooth surface. In addition, plasma spheroidization offers high process yields (routinely exceeding 90%), as the particle size distribution of the product is defined upstream by appropriate sieving of the feedstock, thereby maximizing material utilization.
The atomization process uses metal wire as feedstock. The wire is fed coaxially into the induction plasma discharge, where it is heated until its tip melts.
Once the melting point is reached, the hot plasma gases atomize the metal through a supersonic nozzle at the torch exit. Spherical particles are formed in-flight and directed downwards in a concentrated jet. The reactor is designed to allow particles to solidify before reaching the reactor bottom, preventing contact between the molten metal and any solid surfaces, thereby ensuring high powder purity. The resulting raw powder typically exhibits a particle size distribution up to 200 micron (μm) and specific cut sizes are obtained after classification according to end- use requirements. This technology produces a wide range of dense, spherical powders —including titanium and aluminum alloys — that have become a benchmark in additive manufacturing. Furthermore, the use of hot atomization gas, unlike conventional cold- gas atomization, minimizes the formation of satellite particles at the nozzle exit, where particle concentration in the gas stream is highest.
The atomization process uses metal wire as feedstock. The wire is fed coaxially into the induction plasma discharge, where it is heated until its tip melts.
Once the melting point is reached, the hot plasma gases atomize the metal through a supersonic nozzle at the torch exit. Spherical particles are formed in-flight and directed downwards in a concentrated jet. The reactor is designed to allow particles to solidify before reaching the reactor bottom, preventing contact between the molten metal and any solid surfaces, thereby ensuring high powder purity. The resulting raw powder typically exhibits a particle size distribution up to 200 micron (μm) and specific cut sizes are obtained after classification according to end- use requirements. This technology produces a wide range of dense, spherical powders —including titanium and aluminum alloys — that have become a benchmark in additive manufacturing. Furthermore, the use of hot atomization gas, unlike conventional cold- gas atomization, minimizes the formation of satellite particles at the nozzle exit, where particle concentration in the gas stream is highest.
When flying at hypersonic speeds — exceeding five times the speed of sound — spacecraft are subjected to extreme aerodynamic heating, particularly at their leading edges.
To withstand these conditions, advanced materials used as heat shield (or thermal barrier) are required, capable of resisting extreme temperatures, oxidation, shear stress, and severe thermal gradients. Their development relies on specialized ground- based facilities able to realistically reproduce atmospheric re-entry conditions, including spacecraft velocity, altitude and geometry, as well as atmospheric composition and associated heat flux.
PlasmaSonic is a ground testing facility developed by Tekna for the characterization and development of heat shield materials. It reproduces the severe thermal and aerodynamic environments experienced by high-velocity objects and re-entry vehicles. During testing, samples are instrumented to precisely monitor key parameters such as enthalpy, gas velocity, and heat flux. Combined with validated numerical models, these measurements enable the extrapolation of material performance to full-scale spacecraft and flight profiles.
When flying at hypersonic speeds — exceeding five times the speed of sound — spacecraft are subjected to extreme aerodynamic heating, particularly at their leading edges.
To withstand these conditions, advanced materials used as heat shield (or thermal barrier) are required, capable of resisting extreme temperatures, oxidation, shear stress, and severe thermal gradients. Their development relies on specialized ground- based facilities able to realistically reproduce atmospheric re-entry conditions, including spacecraft velocity, altitude and geometry, as well as atmospheric composition and associated heat flux.
PlasmaSonic is a ground testing facility developed by Tekna for the characterization and development of heat shield materials. It reproduces the severe thermal and aerodynamic environments experienced by high-velocity objects and re-entry vehicles. During testing, samples are instrumented to precisely monitor key parameters such as enthalpy, gas velocity, and heat flux. Combined with validated numerical models, these measurements enable the extrapolation of material performance to full-scale spacecraft and flight profiles.
With over 30 years of experience in applying the technology we are excited to learn what application you have in mind. We support our partners through theoretical modeling, testing campaigns, and joint R&D initiatives. Explore our systems and materials or contact us to start the conversation.
