Abstract: An improved electrode for use in a plasma arc torch. The electrode includes an electrode body, a bore defined by and disposed in the electrode body, and an insert disposed in the bore. The insert and/or the bore of the electrode are configured to improve retention of the insert in the electrode, thereby extending electrode life. The invention also includes a method for forming the electrode. The method includes a step of positioning an insert into a bore of an electrode such that an exterior gap is established that is greater than a second gap.

Abstract: An electrode for a contact start plasma arc torch includes an elongated electrode body formed of an electrically conductive material. The electrode body is movable relative to the torch. A resilient element is used for passing substantially all of a pilot arc current between a power supply, a power connection in electrical communication with the power supply, and the electrode body during pilot arc operation of the plasma arc torch. The electrode and torch can include a contact element having a first surface in electrical communication with the power contact and a second surface for physical contact and electrical communication with a corresponding contact surface of the electrode body for passing substantially all of a transferred arc current between the power supply and the electrode body during transferred arc mode.

Abstract: An electrode for a contact start plasma arc torch includes an elongated electrode body formed of an electrically conductive material that defines a longitudinal axis and a distal end for housing an emissive element. The electrode includes a second end positioned adjacent the electrode body. The second end defines an extensive portion having a first length along a first direction and a second length along a second direction. The second length is greater than the first length. A component for use with the electrode includes a hollow body element having an interior surface with one or more of a contour, step, or flange that defines a shaped opening capable of slideably receiving a complementary-shaped portion of an electrode body.

Abstract: An improved electrode for use in a plasma arc torch. The electrode includes an electrode body, a bore defined by and disposed in the electrode body, and an insert disposed in the bore. The insert and/or the bore of the electrode are configured to improve retention of the insert in the electrode, thereby extending electrode life. The invention also includes a method for forming the electrode. The method includes a step of positioning an insert into a bore of an electrode such that an exterior gap is established that is greater than a second gap.