Abstract: In some aspects, plasma torch cutting systems can include a housing and a plasma torch power supply within the housing and configured to generate a signal that initiates generation of a plasma arc in a torch head, the power supply including an integrated circuit comprising a plurality of electronic components used to generate the signal that initiates generation of the plasma arc, at least one of the electronic components being at least partially formed of a wide bandgap semiconductor material.

Abstract: A consumable set is provided that is usable in a plasma arc torch to direct a plasma arc to a processing surface of a workpiece. The consumable set comprises a nozzle and an alignment surface. The nozzle includes: 1) a nozzle body defining a longitudinal axis extending therethrough, and 2) a nozzle exit orifice disposed in the nozzle body for constricting the plasma arc. The nozzle exit orifice defines an exit orifice axis oriented at a non-zero bevel angle relative to the longitudinal axis. The alignment surface is generally parallel to the longitudinal axis and substantially planar. The alignment surface is dimensioned to orient the nozzle exit orifice such that the plasma arc impinges on the processing surface of the workpiece at the bevel angle while the plasma arc torch is substantially perpendicular to the processing surface.

Abstract: A component for a contact start plasma arc torch is provided. The component includes a hollow body defining a channel with a longitudinal axis. The channel is capable of slideably receiving an electrode body along the longitudinal axis. The component includes a contact element disposed in the hollow body and includes a first surface and a second surface. The first surface is adapted to facilitate electrical communication with a power supply and the second surface is adapted to physically contact a surface of the electrode body when the plasma arc torch is operated in a transferred arc mode. In addition, the second surface is characterized by the absence of physical contact with the surface of the electrode body when the torch is operated in a pilot arc mode.

Abstract: The invention features methods and apparatuses for establishing operational settings of a plasma arc cutting system. A plasma power supply includes a user selectable control. The user selectable control enables selection of a single cutting persona that establishes at least a current, a gas pressure or gas flow rate, and an operational mode of the plasma arc cutting system.

Abstract: In some aspects, a plasma processing torch can include an end portion that receives at least one gas and at least one power input; a first joint coupled to the end portion, the first joint conveying the gas and power through the first joint; a middle portion coupled to the first joint, the middle portion conveying the gas and power through the middle portion; a second joint coupled to the middle portion at an end opposite the first joint, the pivot joint conveying the gas and power through the pivot joint; and a head portion coupled to the second joint, the head portion conveying the gas and power to a torch tip to generate a plasma arc.

Abstract: An electrode for a plasma arc torch includes a generally cylindrical elongated body formed of an electrically conductive material. The elongated body includes a proximal end that connects to a power supply and a distal end that receives an emissive element. The electrode can include a flange that is disposed about a surface relative to the distal end of the elongated body, extends radially from the surface of the elongated body, and is utilized to establish a uniform gas flow distribution of a plasma gas flow about the distal end of the elongated body. The electrode can include a contact element that is in electrical communication with the proximal end of the electrode. The contact element includes seating portion that has an outer width that is greater than the outermost diameter of the electrode body and is configured to position the contact element within the plasma arc torch.

Abstract: A torch tip for a plasma arc torch includes a body having a first end, configured to attach to the torch, and a second end, where an end wall is disposed. A plasma exit orifice is formed in the end wall. At least two castellations are formed in the end wall. Each castellation has a castellation width defined by the distance between the sidewalls of that castellation. At least one slot is disposed between two castellations. Each slot has a slot width defined by a distance between the sidewalls of its adjacent castellations. The slot width can be at least twice the castellation width. Each slot also has a slot floor and an exterior shape. The slot floor can have slope that tapers toward the first end of the body in an outward radial direction and the exterior shape of the slot can have a generally V-shaped or U-shaped contour.

Abstract: In some aspects, methods of initiating a plasma arc in a plasma cutting system can include providing a plasma gas supply lead line extending between a power supply and a plasma arc cutting torch, where the lead line has a first segment proximate to the power supply and a second segment proximate to the torch, and an in-line valve within the lead line between the first segment and the second segment; selectively closing the in-line valve to capture a static volume of gas in the first segment; establishing a decayable volume of gas in the second segment; and initiating the plasma arc when a pressure of the decayable volume reaches a pressure value within a predetermined range.

Abstract: An automated material processing system is provided for processing a workpiece using a processing table. The system includes a replaceable component comprising at least one cutting head consumable, one or more radio frequency identification (RFID) signal devices disposed in or on the replaceable component, and at least one reader communicatively connected to the one or more signal devices. The one or more signal devices are encoded with information about the replaceable component and the reader is configured to sense the information encoded on the one or more signal devices. In addition, the system includes a computing device communicatively connected to the reader for (i) processing the information transmitted by the reader and (ii) configuring a set of operating parameters of the material processing system based on the sensed information.

Abstract: An orifice assembly for a liquid jet cutting system includes a generally cylindrical base, an orifice member, and an orifice cap. The base includes a conduit that extends through a central axis from a top surface to a bottom surface of the base. The base also includes a pedestal that defines a protrusion from the top surface, the pedestal having a planar top region substantially parallel to the planar bottom region of the base. The orifice member sits on the planar top region of the pedestal. The orifice member defines an intermediate conduit therethrough, the intermediate conduit in fluid communication with the base conduit. The orifice cap defines an upper conduit therethrough, the upper conduit in fluid communication with the intermediate conduit of the orifice member. The orifice cap is configured to secure the orifice member to the pedestal.

Abstract: Systems and methods are provided for adjusting a laser beam applied to a workpiece in a processing operation. A laser processing system receives the laser beam that is associated with a beam quality property. The laser processing system adjusts the laser beam to change the beam quality property based on a characteristic of the workpiece, a characteristic of the processing operation, or a combination thereof. The adjusted laser beam can also be delivered to the workpiece.

Abstract: In some aspects, nozzles for gas-cooled plasma torches can include a body having a first end and a second end that define a longitudinal axis; a plenum region substantially formed within the body that extends from the first end and is configured to receive a plasma gas flow; an exit orifice located at the second end oriented substantially coaxially with the longitudinal axis, the exit orifice fluidly connected to the plenum region; and a feature on an outer surface of the body to increase cooling by receiving a high velocity cooling gas flow flowing in a direction along a length of the body, an impingement surface of the feature to receive the cooling gas flow at a substantially perpendicular direction relative to the impingement surface and to redirect the cooling gas flow to promote cooling and uniform shield flow.

Abstract: A method of operating a plasma arc torch system is provided. A first plasma gas supply source, a second plasma gas supply source, and a control unit are provided. A first plasma gas composition is flowed through a first plasma gas flow path, and a plasma arc is generated using the first plasma gas composition. After arc generation, the plasma gas composition is changed to a second plasma gas composition, and the plasma gas flow path is changed to a second plasma gas flow path, wherein the second plasma gas flow path is different from the first plasma gas flow path. The plasma arc is sustained using the second plasma gas composition. The first and second plasma gas flow paths are both at least partially disposed within the plasma arc torch.

Abstract: An orifice assembly for a liquid jet cutting system includes a generally cylindrical base, an orifice member, and an orifice cap. The base includes a conduit that extends through a central axis from a top surface to a bottom surface of the base. The base also includes a pedestal that defines a protrusion from the top surface, the pedestal having a planar top region substantially parallel to the planar bottom region of the base. The orifice member sits on the planar top region of the pedestal. The orifice member defines an intermediate conduit therethrough, the intermediate conduit in fluid communication with the base conduit. The orifice cap defines an upper conduit therethrough, the upper conduit in fluid communication with the intermediate conduit of the orifice member. The orifice cap is configured to secure the orifice member to the pedestal.

Abstract: A power supply assembly for a plasma arc torch is provided. The power supply assembly includes an input circuit, an energy storage device, a torch connector and an output circuit. The input circuit is configured to produce a first output signal. The energy storage device is electrically connected to the input circuit for receiving a charge signal therefrom. The energy storage device is capable of producing a second output signal. The torch connector is electrically connected to the input circuit and the energy storage device for receiving the first and second output signals through the output circuit. The torch connector is configured to supply at least one of the first or second output signal to the plasma arc torch to sustain a plasma arc.

Abstract: Transformer flux is monitored to determine if an onset of flux saturation is detected. If flux saturation is not detected, the transformer drive signal is received to a switch that maintains the polarity of the transformer flux. If flux saturation is detected, the transformer drive signal is received by a switch that reverses the polarity of the transformer signal and the transformer flux. This reversal of flux polarity can occur multiple times, during the carrier cycle of the drive signal, without compromising the dynamics of the transformer main control loop or requiring the drive signal to be regenerated.

Abstract: A consumable component of a liquid jet cutting system is provided. The consumable component includes a body defining a conduit for a liquid jet and a signal device located on or within the body for transmitting a signal associated with the consumable component to a reader.

Abstract: In some aspects, lead connector assemblies for plasma arc torches for providing electrical and fluid connections can include male and female connectors. The female connector can include a current conductive member, a sealing member, clearance region, binding region, and a locking ring having a locking flange. The male connector can include a body defining an internal fluid passage, an electrical contact region, a sealing region, a locking trough, and a driving lip. The male connector, when assembled to the female connector, typically has an engaged configuration and a disengaged configuration. In the engaged configuration, the male connector is locked within the female connector, the electrical contact region forms an electrical connection with the current conducting member, the sealing region forms a seal against the sealing member, the locking trough receives the locking flange, and the locking flange is positioned between the driving lip and the binding region.

Abstract: In some aspects, nozzles for a gas-cooled plasma torches can include a hollow generally cylindrical body having a first end and a second end that define a longitudinal axis, the second end of the body defining a nozzle exit orifice; a gas channel formed in the first end between an interior wall and an exterior wall of the cylindrical body, the gas channel directing a gas flow circumferentially about at least a portion of the body; an inlet passage formed substantially through a radial surface of the exterior wall and fluidly connected to the gas channel; and an outlet passage at least substantially aligned with the longitudinal axis and fluidly connected to the gas channel.

Abstract: A consumable set is provided that is usable in a plasma arc torch to direct a plasma arc to a processing surface of a workpiece. The consumable set includes a nozzle having: 1) a nozzle body defining a longitudinal axis extending therethrough, and 2) a nozzle exit orifice, disposed in the nozzle body, for constricting the plasma arc. The nozzle exit orifice defines an exit orifice axis oriented at a non-zero angle relative to the longitudinal axis. The consumable set can also include an alignment surface generally parallel to the exit orifice axis. The alignment surface is dimensioned to align the exit orifice such that the plasma arc impinges orthogonally on the processing surface.