Abstract: A method of starting an auto-ignition gas torch includes increasing a flow of oxygen above zero and increasing a flow of fuel gas to a level lower than the flow of oxygen for improved start reliability. In one form, the flow of oxygen is from about two times to about six times higher than the flow of fuel gas.

Abstract: A method of directing a gas flow in a tip of a gas torch includes: directing a flow of gas to an outer passageway of the tip; directing the flow of gas inwardly through at least one intermediate gas passageway; directing the flow of gas to a central gas passageway of the tip; and directing the flow of gas distally through a distal orifice of the tip.

Abstract: A method of directing gas flows in a gas torch includes directing a flow of a first gas and a flow of a second gas to a mixer central gas passageway of a mixer and directing the flow of the mixed first and second gases from the mixer to an axial passageway of a tip. The method further includes directing a flow of a third gas to an outer passageway of the tip, directing the flow of the third gas inwardly through at least one intermediate gas passageway, and then directing the flow of the third gas to a tip central gas passageway of the tip. Finally, the flow of the mixed first and second gases and the flow of the third gas are directed distally through a distal portion of the tip.

Abstract: An electrode for a plasma arc torch is provided by the teachings of the present disclosure. In one form, the electrode includes a conductive body, a plurality of deformed emissive inserts, and a dimple. In one form, the plurality of emissive inserts are concentrically nested about the centerline of the conductive body, and the dimple is positioned concentrically about a centerline of the conductive body. The plurality of emissive inserts and the dimple increase the life of the electrode.

Abstract: A tip for use in a gas cutting torch is provided that includes an outer tip portion defining a central cavity and a distal orifice and an inner tip portion disposed within the cavity of the outer tip portion. The inner tip portion defines an outer surface, a central gas passageway in communication with the distal orifice of the outer tip portion, and an least one intermediate gas passageway extending from the outer surface to the central gas passageway for a flow of at least one gas to provide improved cooling to the tip.

Abstract: A tip assembly for use in a gas cutting torch is provided that includes a tip and a mixer. The tip includes a tip central gas passageway and a distal orifice and the mixer includes a proximal end portion and a distal end portion. The distal end portion of the mixer is adapted for connection to the tip and the proximal end portion of the mixer defines a connecting member that removably connects the mixer to a torch head.

Abstract: A component for use in a plasma arc torch is provided that includes an orifice that defines a continuously changing cross-sectional size along the length of a surface of the orifice from an inlet portion to an outlet portion. The surface extends along the component and directs a flow of shield gas at a predetermined angle to result in a specific pierce or cut location on a workpiece. In one form, the component is a shield cap. The continuously changing surface may be convergent, divergent, or a combination of convergent and divergent according to the principles of the present disclosure. Additionally, the shield cap may comprise a single, unitary piece or alternately a plurality of pieces or components.

Abstract: An electrode for a plasma arc torch is provided by the teachings of the present disclosure. In one form, the electrode includes a conductive body, a plurality of deformed emissive inserts, and a dimple. In one form, the plurality of emissive inserts are concentrically nested about the centerline of the conductive body, and the dimple is positioned concentrically about a centerline of the conductive body. The plurality of emissive inserts and the dimple increase the life of the electrode.

Abstract: A tip for use in a gas cutting torch is provided that includes an outer tip portion defining a central cavity and a distal orifice and an inner tip portion disposed within the cavity of the outer tip portion. The inner tip portion defines an outer surface, a central gas passageway in communication with the distal orifice of the outer tip portion, and an least one intermediate gas passageway extending from the outer surface to the central gas passageway for a flow of at least one gas to provide improved cooling to the tip.

Abstract: A tip assembly for use in a gas cutting torch is provided that includes a tip and a mixer. The tip includes a tip central gas passageway and a distal orifice and the mixer includes a proximal end portion and a distal end portion. The distal end portion of the mixer is adapted for connection to the tip and the proximal end portion of the mixer defines a connecting member that removably connects the mixer to a torch head.

Abstract: A method of starting an auto-ignition gas torch includes increasing a flow of oxygen above zero and increasing a flow of fuel gas to a level lower than the flow of oxygen for improved start reliability. In one form, the flow of oxygen is from about two times to about six times higher than the flow of fuel gas.

Abstract: Methods of forming an electrode for use in a plasma arc torch are provided that generally include forming an electrode body defining a proximal end portion and a distal end portion, forming a recess within the distal end portion, securing a slug within the recess of the distal end portion, creating a bore through the slug and the distal end portion of the electrode body, and securing an emissive insert within the bore. In another form, a hybrid electrode is provided, which is formed by the manufacturing methods of the present invention, and which includes an electrode body defining a cavity, a secondary body secured to the electrode body, and an emissive element secured within the bore and in contact with the secondary body and the electrode body, wherein the secondary body is not exposed to the cavity.

Abstract: In a plasma arc torch parts distribution network, the present invention provides a method of providing plasma arc torch parts for use in a single plasma arc torch model through a plurality of distribution channels. In one form of the present invention, the method comprises the steps of providing a first set of plasma arc torch parts to a replacement parts distributor, providing a second set of plasma arc torch parts to an original equipment manufacturer, and providing a third set of plasma arc torch parts to a select original equipment manufacturer. The first, second, and third set of plasma arc torch parts are not interchangeable such that the replacement parts distributor, the original equipment manufacturer, and the select original equipment manufacturer maintain separate inventories of plasma arc torch parts.