Abstract: In some aspects, autonomous motion devices configured to operably connect to a plasma torch of a plasma cutting system can include: a body to support a power supply of the plasma cutting system and move relative to a workpiece; a torch holder connected to the body and configured to position a plasma arc torch tip of the plasma torch relative to a region of the workpiece to be processed; a drive system to translate the body supporting the power supply and torch autonomously relative to a surface of the workpiece during a plasma processing operation; and a processor in communication with the drive system and configured to communicate with the power supply, the processor being configured to control the translation of the body relative to the workpiece in accordance with the plasma processing operation.

Abstract: A consumable set for a plasma arc torch is provided. The consumable set comprises a consumable tip including a plurality of consumable components, at least one of which includes an asymmetric feature asymmetrically disposed in the consumable tip relative to a longitudinal axis. The consumable set also includes a mounting element for coupling the consumable tip to a torch body. The mounting element is configured to axially secure the consumable tip relative to the torch body while permitting independent rotation of the consumable tip relative to the longitudinal axis during assembly. The mounting element is also configured to both axially and radially fix the consumable tip with respect to the torch body such that the asymmetric feature is locked at the specific radial orientation relative to the longitudinal axis after securement.

Abstract: A method for visually communicating material processing parameters to an operator of a torch system. The method includes receiving data related to a material processing operation from at least one sensor of a torch system and at least one camera disposed on a protective helmet. The method further includes processing the data into information relating to a set of material processing parameters and converting the information into visual data compatible with a display disposed on or within the protective helmet. The method also includes providing the visual data to a region of the display for viewing by an operator of the torch system. The region of the display is within a field of view of the operator in order to visually communicate the information to the operator of the torch system.

Abstract: In some aspects, autonomous motion devices configured to operably connect to a plasma torch of a plasma cutting system can include: a body to support a power supply of the plasma cutting system and move relative to a workpiece; a torch holder connected to the body and configured to position a plasma arc torch tip of the plasma torch relative to a region of the workpiece to be processed; a drive system to translate the body supporting the power supply and torch autonomously relative to a surface of the workpiece during a plasma processing operation; and a processor in communication with the drive system and configured to communicate with the power supply, the processor being configured to control the translation of the body relative to the workpiece in accordance with the plasma processing operation.

Abstract: In some aspects, autonomous motion devices configured to operably connect to a plasma torch of a plasma cutting system can include: a body to support a power supply of the plasma cutting system and move relative to a workpiece; a torch holder connected to the body and configured to position a plasma arc torch tip of the plasma torch relative to a region of the workpiece to be processed; a drive system to translate the body supporting the power supply and torch autonomously relative to a surface of the workpiece during a plasma processing operation; and a processor in communication with the drive system and configured to communicate with the power supply, the processor being configured to control the translation of the body relative to the workpiece in accordance with the plasma processing operation.

Abstract: A torch tip assembly of a plasma arc torch is provided for delivering a diffused stream of plasma arc in a gouging operation. The assembly comprises a nozzle including a nozzle body defining a central longitudinal axis extending between a proximal end and a distal end. A nozzle exit orifice of the nozzle body defines at least a bore for conducting the plasma arc therethrough. The assembly also comprises a counter bore feature, disposed relative to the distal end the nozzle body, fluidly connected to the bore and located distally relative to the bore. At least one of the bore or the counter bore feature has a non-circular cross-sectional shape in a plane perpendicular to the longitudinal axis. The non-circular cross-sectional shape is configured to enable a second non-circular cross-sectional shape in the plasma arc that diffuses the plasma arc.

Abstract: A system to prevent a flow of gas and particulates from spreading to atmosphere during a material processing operation includes a slag deflector disposed proximate a torch during the material processing operation. The slag deflector includes a thermally-conductive base portion having an impact surface facing the torch. The impact surface is shaped to prevent the flow of gas and particulates from the material processing operation from spreading in a direction away from the torch, and to redirect the first flow of particulates to a surface configured to inhibit the first flow of particulates from flowing to atmosphere. The slag deflector includes a coolant flow channel configured to thermally-regulate the impact surface of the thermally conductive base portion.

Abstract: A torch tip assembly of a plasma arc torch is provided for delivering a diffused stream of plasma arc in a gouging operation. The assembly comprises a nozzle including a nozzle body defining a central longitudinal axis extending between a proximal end and a distal end. A nozzle exit orifice of the nozzle body defines at least a bore for conducting the plasma arc therethrough. The assembly also comprises a counter bore feature, disposed relative to the distal end the nozzle body, fluidly connected to the bore and located distally relative to the bore. At least one of the bore or the counter bore feature has a non-circular cross-sectional shape in a plane perpendicular to the longitudinal axis. The non-circular cross-sectional shape is configured to enable a second non-circular cross-sectional shape in the plasma arc that diffuses the plasma arc.

Abstract: A consumable set for a plasma arc torch is provided. The consumable set comprises a consumable tip including a plurality of consumable components, at least one of which includes an asymmetric feature asymmetrically disposed in the consumable tip relative to a longitudinal axis. The consumable set also includes a mounting element for coupling the consumable tip to a torch body. The mounting element is configured to axially secure the consumable tip relative to the torch body while permitting independent rotation of the consumable tip relative to the longitudinal axis during assembly. The mounting element is also configured to both axially and radially fix the consumable tip with respect to the torch body such that the asymmetric feature is locked at the specific radial orientation relative to the longitudinal axis after securement.

Abstract: In some aspects, autonomous motion devices configured to operably connect to a plasma torch of a plasma cutting system can include: a body to support a power supply of the plasma cutting system and move relative to a workpiece; a torch holder connected to the body and configured to position a plasma arc torch tip of the plasma torch relative to a region of the workpiece to be processed; a drive system to translate the body supporting the power supply and torch autonomously relative to a surface of the workpiece during a plasma processing operation; and a processor in communication with the drive system and configured to communicate with the power supply, the processor being configured to control the translation of the body relative to the workpiece in accordance with the plasma processing operation.

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 exit orifice axis and dimensioned to align the exit orifice such that the plasma arc impinges orthogonally on the processing surface of the workpiece. The alignment surface is configured to lay at least substantially flush against a guiding surface angled relative to the processing surface of the workpiece.

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 exit orifice axis and dimensioned to align the exit orifice such that the plasma arc impinges orthogonally on the processing surface of the workpiece. The alignment surface is configured to lay at least substantially flush against a guiding surface angled relative to the processing surface of the workpiece.