Abstract: In some aspects, multi-metallic emissive inserts shaped to be disposed within an electrode for a plasma arc torch electrode can include an exposed emitter surface at a distal end of the emissive insert to emit a plasma arc from the electrode, wherein the emissive insert comprises a first emissive material and about 8 weight percent to about 50 weight percent yttrium.

Abstract: A nozzle for a plasma arc cutting torch includes a substantially hollow, elongated body capable of receiving an electrode. The nozzle body defines a longitudinal axis and has a length along the axis from a first end of the nozzle body to a second end of the nozzle body. The nozzle also includes a plasma exit orifice disposed at the first end of the body. The first end of the nozzle body has a width and a ratio of the length of the nozzle body to the width of the nozzle body is greater than about 3.

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: A plasma arc cutting system includes a power supply and a plasma torch attachable to the power supply. The plasma torch generates a plasma arc for cutting a workpiece. A reader is associated with the plasma torch. The reader is capable of reading stored data from an identification device located on a cartridge or a consumable component of the plasma arc cutting system. A controller is within the plasma arc cutting system and in communication with the power supply. The controller is capable of automatically establishing operating parameters of the plasma arc cutting system based upon the data stored on the identification device. An override feature allows a user of the plasma arc cutting system to override the automatically established operating parameters of the torch and to input user selected operating parameters.

Abstract: A portable plasma arc torch system can be used for processing materials. The system includes a replaceable or rechargeable power source and replaceable or rechargeable gas source. A controller communicates with at least one of the power source or the gas source. A plasma delivery device received via the controller current from the power source and gas from the gas source to generate a plasma arc at an output of the plasma delivery device. The plasma arc can be used to process materials such as metallic workpieces. The plasma arc torch can include a wearable portable assembly which includes the replaceable or rechargeable power and gas source. A plasma delivery device receives current from the power source in the assembly and gas from the gas source in the assembly to generate a plasma arc.

Abstract: A nozzle or retaining cap for a plasma arc torch that includes a surface defining a conductive contact portion for exchanging heat with an adjacent torch component. The adjacent torch component can be a retaining cap, electrode or nozzle. The surface of the nozzle or retaining cap can also at least partially define a cooling channel having a curvilinear surface. A sealant portion can be positioned between the conductive contact portion and the cooling channel. The sealant portion can form or create a fluid barrier between the cooling channel and the conductive portion.

Abstract: A method is provided for operating a plasma arc torch system having a power supply and a plasma arc torch. The method includes supplying power to the power supply from a battery. The battery provides at least a portion of the power to generate a plasma arc by the plasma arc torch. The method also includes communicating a first signal, indicating at least one parameter of the battery, between the battery and a control unit of the power supply, generating a second signal, by the control unit, based on the at least one parameter of the battery, and controlling, using the control circuit, operation of the plasma arc torch based on the second signal.

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: The invention features methods and apparatuses for establishing operational settings of a plasma arc cutting system automatically using replaceable cartridges. A replaceable cartridge for use with a plasma arc cutting system includes a housing, a connection mechanism for coupling the housing to a plasma arc torch, an arc constrictor connected to the housing, an arc emitter connected to the housing, and an identification mechanism disposed relative to the housing and configured to communicate information to a reader of the plasma arc cutting system and automatically set at least one operating parameter of the plasma arc cutting system.

Abstract: A method is provided for configuring two thermal processing systems. The method includes providing a first consumable for use in a first thermal processing torch and a second consumable for use in a second thermal processing torch. The first and second consumables have substantially identical physical characteristics. The first and second torches are mounted in a first thermal process system and a second thermal processing system, respectively. The method also includes sensing, by the first thermal processing system, first data stored in a first signal device associated with the first consumable and sensing, by the second thermal processing system, second data stored in a second signal device associated with the second consumable.

Abstract: A consumable component for a thermal processing torch is provided. The consumable component includes a consumable component body and a signal device located on or within the consumable component body for transmitting a signal associated with the consumable component. The signal can be independent of a detectable physical characteristic of the consumable component.

Abstract: A portable plasma arc torch system can be used for processing materials. The system includes a replaceable or rechargeable power source and replaceable or rechargeable gas source. A controller communicates with at least one of the power source or the gas source. A plasma delivery device received via the controller current from the power source and gas from the gas source to generate a plasma arc at an output of the plasma delivery device. The plasma arc can be used to process materials such as metallic workpieces. The plasma arc torch can include a wearable portable assembly which includes the replaceable or rechargeable power and gas source. A plasma delivery device receives current from the power source in the assembly and gas from the gas source in the assembly to generate a plasma arc.

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: A portable plasma arc torch system can be used for processing materials. The system includes a replaceable or rechargeable power source and replaceable or rechargeable gas source. A controller communicates with at least one of the power source or the gas source. A plasma delivery device received via the controller current from the power source and gas from the gas source to generate a plasma arc at an output of the plasma delivery device. The plasma arc can be used to process materials such as metallic workpieces. The plasma arc torch can include a wearable portable assembly which includes the replaceable or rechargeable power and gas source. A plasma delivery device receives current from the power source in the assembly and gas from the gas source in the assembly to generate a plasma arc.

Abstract: A nozzle for a plasma arc cutting torch includes a substantially hollow, elongated body capable of receiving an electrode. The nozzle body defines a longitudinal axis and has a length along the axis from a first end of the nozzle body to a second end of the nozzle body. The nozzle also includes a plasma exit orifice disposed at the first end of the body. The first end of the nozzle body has a width and a ratio of the length of the nozzle body to the width of the nozzle body is greater than about 3.

Abstract: A portable plasma arc torch system can be used for processing materials. The system includes a replaceable or rechargeable power source and replaceable or rechargeable gas source. A controller communicates with at least one of the power source or the gas source. A plasma delivery device received via the controller current from the power source and gas from the gas source to generate a plasma arc at an output of the plasma delivery device. The plasma arc can be used to process materials such as metallic workpieces.

Abstract: A portable plasma arc torch system can be used for processing materials. The system includes a replaceable or rechargeable power source and replaceable or rechargeable gas source. A controller communicates with at least one of the power source or the gas source. A plasma delivery device received via the controller current from the power source and gas from the gas source to generate a plasma arc at an output of the plasma delivery device. The plasma arc can be used to process materials such as metallic workpieces. The plasma arc torch can include a wearable portable assembly which includes the replaceable or rechargeable power and gas source. A plasma delivery device receives current from the power source in the assembly and gas from the gas source in the assembly to generate a plasma arc.

Abstract: A nozzle or retaining cap for a plasma arc torch that includes a surface defining a conductive contact portion for exchanging heat with an adjacent torch component. The adjacent torch component can be a retaining cap, electrode or nozzle. The surface of the nozzle or retaining cap can also at least partially define a cooling channel having a curvilinear surface. A sealant portion can be positioned between the conductive contact portion and the cooling channel. The sealant portion can form or create a fluid barrier between the cooling channel and the conductive portion.

Abstract: A portable plasma arc torch system can be used for processing materials. The system includes a replaceable or rechargeable power source and replaceable or rechargeable gas source. A controller communicates with at least one of the power source or the gas source. A plasma delivery device received via the controller current from the power source and gas from the gas source to generate a plasma arc at an output of the plasma delivery device. The plasma arc can be used to process materials such as metallic workpieces.