Abstract: Vented shield systems for plasma arc torches are provided that comprise a shield cup body defining a distal end portion, a vented retainer secured to the distal end portion of the shield cup body, and a shield cap secured to the vented retainer. The vented retainer defines at least one vent passageway that directs a flow of secondary gas inward toward the shield cap, and the vented shield system blocks at least a portion of molten metal from contacting components, such as a tip or nozzle, of the plasma arc torch. The shield cap may comprise a mechanized cap, a drag cap, a gouging cap, or a deflector cap, among others. Accordingly, various shield caps may be employed without removal or replacement of the vented retainer. The same vented retainer may be used throughout a variety of plasma arc torch applications.

Abstract: A dual mode plasma arc torch and methods of operation thereof are provided, wherein the plasma arc torch is operable with both a high frequency power supply and a contact start power supply.

Abstract: A dual mode plasma arc torch is provided that preferably comprises a start cartridge disposed between an electrode and a tip. In one form, the start cartridge comprises an initiator that is in electrical contact with the electrode and that is resiliently biased into contact with the tip, such that when the plasma arc torch is in a contact start mode, the initiator is movable against the resilient bias to separate from the tip and establish a pilot arc between the initiator and the tip. Further, when the plasma arc torch is in a high frequency start mode, the start cartridge spaces the tip from the electrode such that a pilot arc is established between the electrode and the tip. In other forms, a contact start torch is provided that is operable under high frequency, and conversely, a high frequency start torch is provided that is operable under low voltage.

Abstract: A tip gas distributor is provided that preferably comprises a plurality of swirl holes and a plurality of secondary gas holes, wherein the swirl holes direct a plasma gas to generate a plasma stream, and the secondary gas holes direct a secondary gas to stabilize the plasma stream. Additionally, a tip gas distributor is provided that comprises swirl passages and secondary gas passages formed between the tip gas distributor and an adjacent component to generate and stabilize the plasma stream. Further, methods of generating and stabilizing the plasma stream are provided through the use of the swirl holes and passages, along with the secondary gas holes and passages.

Abstract: A plasma arc torch is provided that comprises a set of torch consumable components secured to a torch head, wherein a supply of cooling fluid flows coaxially through the torch to cool torch components and a supply of plasma gas and secondary gas flows through the torch to generate and stabilize a plasma stream for operations such as cutting workpieces. The torch consumable components, in part, comprise an electrode and a tip that include a variety of configurations for improved cooling, electrical contact, and attachment to adjacent torch components. Further, a consumables cartridge is provided for ease of use and replacement of the torch consumable components. Additionally, methods of operating the plasma arc torch at relatively high current levels are also provided by the present invention.

Abstract: A variety of electrodes for use in a plasma arc torch are provided that improve cooling between the electrode and an adjacent cathodic element such as a cathode. At least one passageway is formed between the electrode and the cathode for the flow of a fluid, e.g. cooling fluid, wherein the flow of the fluid is proximate, or through an adjacent vicinity of, electrical contact between the cathode and the electrode. The passageway is formed through the electrode, through the cathode, between the electrode and the cathode, and through a third element in the various forms of the present invention. Further, methods of operating a plasma arc torch using the electrodes according to the various forms of the invention are also provided.

Abstract: A gas distributor for use in a plasma arc torch is provided that has at least one plasma gas passageway formed conjointly with a metering passageway, and at least one helical gas passageway formed along an interior portion of the gas distributor, wherein the helical gas passageway is in fluid communication with the plasma gas passageway and the metering passageway. The combination of the metering passageway and the helical gas passageway provides for a metered flow rate and a controlled swirling flow of plasma gas within the plasma arc chamber, respectively, which functions to reduce the amount of molten emissive insert that is ejected from within an electrode at arc shut off, thereby resulting in an increased life of the consumable electrode.

Abstract: A plasma arc torch is provided that comprises a set of torch consumable components secured to a torch head, wherein a supply of cooling fluid flows coaxially through the torch to cool torch components and a supply of plasma gas and secondary gas flows through the torch to generate and stabilize a plasma stream for operations such as cutting workpieces. The torch consumable components, in part, comprise an electrode and a tip that include a variety of configurations for improved cooling, electrical contact, and attachment to adjacent torch components. Further, a consumables cartridge is provided for ease of use and replacement of the torch consumable components. Additionally, methods of operating the plasma arc torch at relatively high current levels are also provided by the present invention.

Abstract: A torch lead extension is provided that comprises a conduit having a distal end and a proximal end. The torch lead extension further comprises a distal connector member disposed at the distal end of the conduit and a proximal connector member disposed at the proximal end of the conduit. The distal connector member is engageable with a torch lead connector member secured to a proximal end of a torch lead. The proximal connector member is engageable with a power supply connector member of a power supply. Generally, the distal connector member and the torch lead connector member comprise a distal quick disconnect, and the proximal connector member and the power supply connector member comprise a proximal quick disconnect. Accordingly, the torch lead extension may be quickly assembled between or disassembled from the torch lead and the power supply.

Abstract: A trigger system for operating a plasma arc torch is provided that comprises a selector that operates between at least a first operating position and a second operating position, wherein the first operating position operates the plasma arc torch in a first mode to deliver gas to the plasma arc torch, and the second operating position operates the plasma arc torch in a second mode to deliver the gas and electric power to the plasma arc torch. Further, the selector comprises a neutral position that selects a neutral mode in which delivery of gas and electric power to the plasma arc torch is inhibited. The selector is preferably disposed within a housing of the plasma arc torch and is slidably operable between the first operating position, the second operating position, and the neutral position.

Abstract: A plasma arc torch is provided that comprises a set of torch consumable components secured to a torch head, wherein a supply of cooling fluid flows coaxially through the torch to cool torch components and a supply of plasma gas and secondary gas flows through the torch to generate and stabilize a plasma stream for operations such as cutting workpieces. The torch consumable components, in part, comprise an electrode and a tip that include a variety of configurations for improved cooling, electrical contact, and attachment to adjacent torch components. Further, a consumables cartridge is provided for ease of use and replacement of the torch consumable components. Additionally, methods of operating the plasma arc torch at relatively high current levels are also provided by the present invention.