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 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 plasma arc torch and method for cutting a workpiece in which the torch has a primary gas flow path for receiving a primary working gas and directing it through the torch to a central exit opening of the torch for exhaustion from the torch onto the workpiece in the form of an ionized plasma. A secondary gas flow path in the torch receives a secondary gas separate from the primary working gas and directs it through the torch. The primary gas flow path is in fluid communication with the secondary gas flow path substantially upstream of the central exit opening of the torch to bleed primary working gas in the primary gas flow path into the secondary gas flow path for admixture therewith to form a secondary gas mixture to be exhausted from the torch.

Abstract: A plasma arc torch and method for cutting a workpiece in which the torch has a primary gas flow path for receiving a primary working gas and directing it through the torch to a central exit opening of the torch for exhaustion from the torch onto the workpiece in the form of an ionized plasma. A secondary gas flow path in the torch receives a secondary gas separate from the primary working gas and directs it through the torch. The primary gas flow path is in fluid communication with the secondary gas flow path substantially upstream of the central exit opening of the torch to bleed primary working gas in the primary gas flow path into the secondary gas flow path for admixture therewith to form a secondary gas mixture to be exhausted from the torch.