Abstract: A power module cartridge for a welder includes a chassis tray that is dimensioned to fit inside an external case of the welder. The chassis tray includes a fan receptacle, a capacitor receptacle, a rectifier mounting slot and a transformer receptacle. A fan fits into the fan receptacle; a capacitor fits into the capacitor receptacle; a rectifier plate fits into the rectifier mounting slot; and a transformer fits into the transformer receptacle. The chassis tray can also include a clip for receiving a printed circuit board (“PCB”). The PCB can be electrically connected to the aforementioned components. A second chassis tray can fit on the top of each of the components such that the components are sandwiched between the first and second chassis trays. A method of manufacturing a welder is also disclosed.

Abstract: A modular welding wire feed drive for use in a welding system. The welding wire feed drive is designed to be detachably connected to the welding wire feed system of the welding system. The welding wire feed drive includes a drive housing designed to be detachably connectable to the welding wire feed system, a wire contact arrangement designed to controllably feed welding wire through the welding wire feed drive, and a drive motor that is connected to or interconnected to the wire contact arrangement to at least partially drive the wire contact arrangement.

Abstract: A modular welding wire feed drive for use in a welding system. The welding wire feed drive is designed to be detachably connected to the welding wire feed system of the welding system. The welding wire feed drive includes a drive housing designed to be detachably connectable to the welding wire feed system, a wire contact arrangement designed to controllably feed welding wire through the welding wire feed drive, and a drive motor that is connected to or interconnected to the wire contact arrangement to at least partially drive the wire contact arrangement.

Abstract: A plasma torch comprises a tubular nozzle having an end wall and an electrode in the nozzle having a nose end facing the end wall. The nose end and end wall provide a plasma gas chamber, and the end wall has a gas chamber outlet opening extending axially therethrough. The gas chamber has an entrance radially outwardly of the outlet opening and the end wall has a plurality of arcuate ribs thereon circumferentially spaced apart about said outlet opening and providing a plurality of arcuate gas directing channels for radially guiding the flow of plasma gas in a swirling flow pattern from the entrance to the outlet opening. The nozzle and nozzle mounting components provide an improved arrangement for cooling the torch tip and producing a gas shield about the plasma jet.

Abstract: A plasma torch comprises a tubular nozzle having an end wall and an electrode in the nozzle having a nose end facing the end wall. The nose end and end wall provide a plasma gas chamber, and the end wall has a gas chamber outlet opening extending axially therethrough. The gas chamber has an entrance radially outwardly of the outlet opening and the end wall has a plurality of arcuate ribs thereon circumferentially spaced apart about said outlet opening and providing a plurality of arcuate gas directing channels for radially guiding the flow of plasma gas in a swirling flow pattern from the entrance to the outlet opening. The nozzle and nozzle mounting components provide an improved arrangement for cooling the torch tip and producing a gas shield about the plasma jet.