Abstract: A liquid coolant tube for a plasma arc cutting torch including a hollow elongated inner body shaped to translate within a hollow elongated outer body. The hollow elongated outer body of the liquid coolant tube is shaped to fixedly connect to the plasma arc cutting torch and includes a set of electrode guides. An external surface of the hollow elongated outer body and the set of electrode guides partially define a set of coolant flow channels between the set of electrode guides. The set of electrode guides are shaped to facilitate alignment of an electrode within the plasma arc cutting torch.

Abstract: A liquid cooled electrode for a contact start plasma arc cutting torch is provided. The electrode includes an elongated body defining a longitudinal axis. The elongated body includes a proximal end shaped to matingly engage a torch body of the plasma arc cutting torch and a distal end located substantially opposite of the proximal end along the longitudinal axis. The electrode also includes one or more contact surfaces disposed on an external surface of the distal end of the electrode body between the proximal and distal ends. The one or more contact surfaces are shaped to physically contact a nozzle disposed within the plasma arc cutting torch during a portion of a pilot arc initiation process. The physical contact is configured to support transmission of a pilot arc current between the electrode and the nozzle with a density of at least about 3000 amps per square inch.

Abstract: A liquid coolant tube for a plasma arc cutting torch including a hollow elongated inner body shaped to translate within a hollow elongated outer body. The hollow elongated outer body of the liquid coolant tube is shaped to fixedly connect to the plasma arc cutting torch and includes a set of electrode guides. An external surface of the hollow elongated outer body and the set of electrode guides partially define a set of coolant flow channels between the set of electrode guides. The set of electrode guides are shaped to facilitate alignment of an electrode within the plasma arc cutting torch.

Abstract: In some aspects, torch receptacles for coupling a plasma arc torch to a torch lead can include: a body having a first end to connect to the torch lead and a second end to connect to a torch body; a set of ports within the first end to fluidly connect to a set of fluid conduits within the torch lead; and a multiway valve within the body and fluidly connected to the set of ports and to a torch gas conduit formed in the second end, the multiway valve being configured to: i) manipulate a flow of fluids between the first end and the second end to select from primary gases entering the set of ports, ii) deliver a selected primary gas to the torch body through the torch gas conduit, and iii) fluidly connect the torch gas conduit to a gas supply manifold of the plasma cutting system.

Abstract: A liquid cooled electrode for a contact start plasma arc cutting torch is provided. The electrode includes an elongated body defining a longitudinal axis. The elongated body includes a proximal end shaped to matingly engage a torch body of the plasma arc cutting torch and a distal end located substantially opposite of the proximal end along the longitudinal axis. The electrode also includes one or more contact surfaces disposed on an external surface of the distal end of the electrode body between the proximal and distal ends. The one or more contact surfaces are shaped to physically contact a nozzle disposed within the plasma arc cutting torch during a portion of a pilot arc initiation process. The physical contact is configured to support transmission of a pilot arc current between the electrode and the nozzle with a density of at least about 3000 amps per square inch.

Abstract: A contact start liquid-cooled plasma arc cutting torch is provided that includes a translatable liquid-cooled electrode, a nozzle, and a multi-piece cathode. The electrode comprises an electrode body defining a proximal end and a distal end along a longitudinal axis of the electrode body. The electrode body includes a coolant cavity configured to receive at least a portion of a coolant tube of the torch for directing a liquid coolant flow distally through the coolant tube within the coolant cavity. The cathode is disposed about the proximal end of the electrode body and includes a first body shaped to matingly engage the electrode and a second body shaped to matingly engage the torch. The first body slidingly engages the second body such that the first body and the electrode are axially translatable relative to the second body along the longitudinal axis.

Abstract: A connector component configured for coupling a consumable component to a plasma arc torch is provided. The connector component comprises a body having a proximal end and a distal end disposed along and defining a longitudinal axis. The connector component includes at least two engagement regions disposed radially about the longitudinal axis on a surface of the body. Each engagement region includes at least one engagement feature disposed on the surface of the body. The connector component also includes at least two free regions disposed radially about the longitudinal axis on the surface of the body. Each free region is radially located between a pair of the engagement regions and characterized by an absence of the engagement feature.

Abstract: A connector component (102) is provided for assembly into a material processing torch head. The connector component (102) comprises a generally cylindrical body (104) that includes a proximal end (106) and a distal end (108) defining a longitudinal axis. At least two thread regions (112) are disposed at a radial location on a surface of the body near the proximal end. Each thread region includes at least one thread (114) disposed on the surface of the body. In addition, at least two non-thread regions (116) are oriented longitudinally at a radial location on the surface of the body (104).

Abstract: In some aspects, torch receptacles for coupling a plasma arc torch to a torch lead can include: a body having a first end to connect to the torch lead and a second end to connect to a torch body; a set of ports within the first end to fluidly connect to a set of fluid conduits within the torch lead; and a multiway valve within the body and fluidly connected to the set of ports and to a torch gas conduit formed in the second end, the multiway valve being configured to: i) manipulate a flow of fluids between the first end and the second end to select from primary gases entering the set of ports, ii) deliver a selected primary gas to the torch body through the torch gas conduit, and iii) fluidly connect the torch gas conduit to a gas supply manifold of the plasma cutting system.

Abstract: In some aspects, torch receptacles for coupling a plasma arc torch to a torch lead can include: a body having a first end to connect to the torch lead and a second end to connect to a torch body; a set of ports within the first end to fluidly connect to a set of fluid conduits within the torch lead; and a multiway valve within the body and fluidly connected to the set of ports and to a torch gas conduit formed in the second end, the multiway valve being configured to: i) manipulate a flow of fluids between the first end and the second end to select from primary gases entering the set of ports, ii) deliver a selected primary gas to the torch body through the torch gas conduit, and iii) fluidly connect the torch gas conduit to a gas supply manifold of the plasma cutting system.

Abstract: In some aspects, torch receptacles for coupling a plasma arc torch to a torch lead can include: a body having a first end to connect to the torch lead and a second end to connect to a torch body; a set of ports within the first end to fluidly connect to a set of fluid conduits within the torch lead; and a multiway valve within the body and fluidly connected to the set of ports and to a torch gas conduit formed in the second end, the multiway valve being configured to: i) manipulate a flow of fluids between the first end and the second end to select from primary gases entering the set of ports, ii) deliver a selected primary gas to the torch body through the torch gas conduit, and iii) fluidly connect the torch gas conduit to a gas supply manifold of the plasma cutting system.

Abstract: The invention features methods and apparatuses for liquid cooling a plasma arc torch. An electrode is provided including a body having a longitudinal axis defining a first end, a second end, and a middle portion. The electrode includes a first sealing element disposed on an exterior of the body near the first end; a second sealing element disposed on the exterior of the body located in the middle portion, the second sealing element configured to provide a first gas seal to a swirl gas chamber and defining a portion of the swirl gas chamber; and a third sealing element disposed on the exterior of the body, the third sealing element located between the second sealing element and the second end, the third sealing element configured to provide a second gas seal to the swirl gas chamber and defining a portion of the swirl gas chamber.

Abstract: A connector component configured for coupling a consumable component to a plasma arc torch is provided. The connector component comprises a body having a proximal end and a distal end disposed along and defining a longitudinal axis. The connector component includes at least two engagement regions disposed radially about the longitudinal axis on a surface of the body. Each engagement region includes at least one engagement feature disposed on the surface of the body. The connector component also includes at least two free regions disposed radially about the longitudinal axis on the surface of the body. Each free region is radially located between a pair of the engagement regions and characterized by an absence of the engagement feature.

Abstract: The invention features methods and apparatuses for liquid cooling a plasma arc torch. An electrode is provided including a body having a longitudinal axis defining a first end, a second end, and a middle portion. The electrode includes a first sealing element disposed on an exterior of the body near the first end; a second sealing element disposed on the exterior of the body located in the middle portion, the second sealing element configured to provide a first gas seal to a swirl gas chamber and defining a portion of the swirl gas chamber; and a third sealing element disposed on the exterior of the body, the third sealing element located between the second sealing element and the second end, the third sealing element configured to provide a second gas seal to the swirl gas chamber and defining a portion of the swirl gas chamber.

Abstract: In some aspects, torch receptacles for coupling a plasma arc torch to a torch lead can include: a body having a first end to connect to the torch lead and a second end to connect to a torch body; a set of ports within the first end to fluidly connect to a set of fluid conduits within the torch lead; and a multiway valve within the body and fluidly connected to the set of ports and to a torch gas conduit formed in the second end, the multiway valve being configured to: i) manipulate a flow of fluids between the first end and the second end to select from primary gases entering the set of ports, ii) deliver a selected primary gas to the torch body through the torch gas conduit, and iii) fluidly connect the torch gas conduit to a gas supply manifold of the plasma cutting system.

Abstract: A connector component is provided for assembly into a torch. The connector component comprises a body that includes a proximal end and a distal end disposed along a longitudinal axis. At least two thread regions are disposed radially about the longitudinal axis on a surface of the body near the proximal end. Each thread region includes at least two parallel threads disposed on the surface of the body. In addition, at least two smooth regions are each disposed radially about the longitudinal axis between a pair of thread regions on the surface of the body.

Abstract: A connector component (102) is provided for assembly into a material processing torch head. The connector component (102) comprises a generally cylindrical body (104) that includes a proximal end (106) and a distal end (108) defining a longitudinal axis. At least two thread regions (112) are disposed at a radial location on a surface of the body near the proximal end. Each thread region includes at least one thread (114) disposed on the surface of the body. In addition, at least two non-thread regions (116) are oriented longitudinally at a radial location on the surface of the body (104).

Abstract: A connector component is provided for assembly into a torch. The connector component comprises a body that includes a proximal end and a distal end disposed along a longitudinal axis. At least two thread regions are disposed radially about the longitudinal axis on a surface of the body near the proximal end. Each thread region includes at least two parallel threads disposed on the surface of the body. In addition, at least two smooth regions are each disposed radially about the longitudinal axis between a pair of thread regions on the surface of the body.