Abstract: An electrode for a liquid-cooled plasma arc torch is provided that includes a torch body and a cathodic element. The electrode includes an electrode body having a proximal end and a distal end extending along a central longitudinal axis. The electrode also includes a retention region located at the proximal end of the electrode body. The retention region is shaped to engage a first portion of the torch body for retaining the electrode within the torch body. The electrode additionally includes a current interface region located axially proximal to the retention region on the electrode body. The current interface region configured to slidably engage a second portion of the torch body while electrically communicating with the cathodic element of the plasma arc torch. The electrode further includes a sealing member circumferentially disposed about the electrode body. The sealing member is located axially distal to the current interface region and the retention region.

Abstract: An electrode for a consumable cartridge of a plasma arc torch is provided. The electrode comprises a substantially hollow body defining a proximal end, a distal end and a longitudinal axis extending therebetween. The electrode also includes a plurality of flanges, including a proximal flange and a distal flange, disposed circumferentially about an external surface of the hollow body and extending radially outward. Each flange defines one or more holes configured to conduct a gas flow therethrough along the external surface of the hollow body. The one or more holes on the proximal flange define a first combined cross-sectional flow area that is different from a second combined cross-sectional flow area defined by the one or more holes on the distal flange.

Abstract: A first connector is disposed on a first end of a lead in a lead set for use with a plasma arc torch. The first connector is capable of engaging a second connector by causing a compression force in a second connector. The second connector compression force is caused by application of a translational force along a longitudinal axis. The second connector causes, upon application of a depression force along the longitudinal axis, disengagement of the first connector. The second causes disengagement of the first connector upon application of a linear force applied along the longitudinal axis to at least one of the first connector and the second connector. The second end of the lead may also be connected to a power supply. Methods for connecting and disconnecting a lead are also disclosed.

Abstract: A coolant tube and electrode are adapted to mate with each other to align the tube relative to the electrode during operation of the torch. Improved alignment ensures an adequate flow of coolant along an interior surface of the electrode. In one aspect, an elongated body of the coolant tube has a surface adapted to mate with the electrode. In another aspect, an elongated body of the electrode has a surface adapted to mate with the coolant tube. The surfaces of the tube and electrode may, for example, be flanges, tapered surfaces, contours, or steps.

Abstract: A coolant tube and electrode are adapted to mate with each other to align the tube relative to the electrode during operation of the torch. Improved alignment ensures an adequate flow of coolant along an interior surface of the electrode. In one aspect, an elongated body of the coolant tube has a surface adapted to mate with the electrode. In another aspect, an elongated body of the electrode has a surface adapted to mate with the coolant tube. The surfaces of the tube and electrode may, for example, be flanges, tapered surfaces, contours, or steps.

Abstract: A coolant tube and electrode are adapted to mate with each other to align the tube relative to the electrode during operation of the torch. Improved alignment ensures an adequate flow of coolant along an interior surface of the electrode. In one aspect, an elongated body of the coolant tube has a surface adapted to mate with the electrode. In another aspect, an elongated body of the electrode has a surface adapted to mate with the coolant tube. The surfaces of the tube and electrode may, for example, be flanges, tapered surfaces, contours, or steps.

Abstract: The invention features an apparatus and method for using a plasma arc torch to cut a workpiece in a cavity. The torch includes an adapter connectable to a torch body and remote torch head, establishing a spaced relationship between them, for positioning the torch head adjacent the workpiece in the cavity. The system includes a grounding member useful for operating the torch in a transferred mode, a clamping plate for retaining a severed portion of the workpiece, and a torch tip design that allows the torch head to be positioned within the cavity.