Abstract: A torch tip is provided for a liquid-cooled plasma arc cutting torch. The torch tip includes an electrode with an elongated electrode body having a distal end and a proximal end extending along a longitudinal axis. The electrode body includes at least one interior threaded connection at the proximal end for engaging a liquid-cooled electrode holder. The electrode holder comprises a liquid coolant channel that does not extend into the electrode body. The electrode body has (i) a length extending along the longitudinal axis and (ii) a diameter associated with a widest portion of the electrode body along the longitudinal axis between the proximal and distal ends, where a ratio of the length to the diameter of the electrode body is greater than about 5.

Abstract: A computerized method is provided for selecting a direction of formation of a slag puddle on a workpiece during processing of the workpiece by a thermal processing torch. The method comprises causing the torch to emit a thermal arc to gouge the workpiece at a first location without piercing through the workpiece. The method also includes translating the torch from the first location to a second location along a first direction on the workpiece while the torch is gouging the workpiece, the first direction substantially along the selected direction of slag puddle formation. The gouging and translating cause formation of a trench in a surface of the workpiece in the first direction. The method further includes causing the thermal arc emitted by the torch to pierce through the workpiece at the second location, which causes the formation of the slag puddle along the selected direction as guided by the trench.

Abstract: In some aspects, a plasma torch head for a plasma arc torch can include ports disposed within a base portion that are configured to receive fluids and electrical signals from a plasma torch lead via a plasma torch receptacle, the ports being shaped to align the torch head and the plasma torch receptacle during connection and including: a central coolant supply port to convey a liquid coolant to the torch head, the central coolant supply port extending a length to primarily align the plasma torch head with the torch receptacle, the central coolant supply port further including a flat surface shaped to secondarily align the torch head with the torch receptacle upon mating engagement, and an ohmic contact connector defining a tertiary alignment feature; and a connector disposed about the base portion shaped to engage with and couple to the torch receptacle.

Abstract: In some aspects, a plasma torch head for a plasma arc torch can include ports disposed within a base portion that are configured to receive fluids and electrical signals from a plasma torch lead via a plasma torch receptacle, the ports being shaped to align the torch head and the plasma torch receptacle during connection and including: a central coolant supply port to convey a liquid coolant to the torch head, the central coolant supply port extending a length to primarily align the plasma torch head with the torch receptacle, the central coolant supply port further including a flat surface shaped to secondarily align the torch head with the torch receptacle upon mating engagement, and an ohmic contact connector defining a tertiary alignment feature; and a connector disposed about the base portion shaped to engage with and couple to the torch receptacle.

Abstract: A torch tip is provided for a liquid-cooled plasma arc cutting torch. The torch tip includes an electrode with an elongated electrode body having a distal end and a proximal end extending along a longitudinal axis. The electrode body includes at least one interior threaded connection at the proximal end for engaging a liquid-cooled electrode holder. The electrode holder comprises a liquid coolant channel that does not extend into the electrode body. The electrode body has (i) a length extending along the longitudinal axis and (ii) a diameter associated with a widest portion of the electrode body along the longitudinal axis between the proximal and distal ends, where a ratio of the length to the diameter of the electrode body is greater than about 5.

Abstract: A connector component configured for coupling a consumable component to a plasma arc torch is provided. The connector component comprises a body having a proximal end and a distal end disposed along and defining a longitudinal axis. The connector component includes at least two engagement regions disposed radially about the longitudinal axis on a surface of the body. Each engagement region includes at least one engagement feature disposed on the surface of the body. The connector component also includes at least two free regions disposed radially about the longitudinal axis on the surface of the body. Each free region is radially located between a pair of the engagement regions and characterized by an absence of the engagement feature.

Abstract: In some aspects, methods for limiting damage to a plasma arc torch body resulting from a consumable failure within the torch can include determining a specified conductivity parameter set point of a current to be provided to the plasma arc torch for a material processing operation; measuring a detected conductivity parameter of plasma arc current being provided to the plasma torch to perform the material processing operation; comparing the specified conductivity parameter set point to the detected conductivity parameter of plasma arc current and calculating an error term signal; and based on a determination that the error term signal exceeds a threshold amount, initiating a plasma arc shut down sequence to extinguish the plasma arc to limit damage to the plasma arc torch body.

Abstract: A connector component (102) is provided for assembly into a material processing torch head. The connector component (102) comprises a generally cylindrical body (104) that includes a proximal end (106) and a distal end (108) defining a longitudinal axis. At least two thread regions (112) are disposed at a radial location on a surface of the body near the proximal end. Each thread region includes at least one thread (114) disposed on the surface of the body. In addition, at least two non-thread regions (116) are oriented longitudinally at a radial location on the surface of the body (104).

Abstract: A plasma cutting system is provided. The system includes a torch tip having a proximal end and a distal end defining a longitudinal axis extending therethrough. The torch tip includes a plasma plenum and a plasma arc exit orifice located at the distal end of the torch tip. The system includes a lead having a distal end configured for connection to the proximal end of the torch tip. The system also includes an atmospheric vent port disposed between the plasma arc exit orifice and the distal end of the lead. The system further includes a conduit fluidly connecting the plasma plenum and the atmospheric vent port.

Abstract: The invention features methods and apparatuses for liquid cooling a plasma arc torch. An electrode is provided including a body having a longitudinal axis defining a first end, a second end, and a middle portion. The electrode includes a first sealing element disposed on an exterior of the body near the first end; a second sealing element disposed on the exterior of the body located in the middle portion, the second sealing element configured to provide a first gas seal to a swirl gas chamber and defining a portion of the swirl gas chamber; and a third sealing element disposed on the exterior of the body, the third sealing element located between the second sealing element and the second end, the third sealing element configured to provide a second gas seal to the swirl gas chamber and defining a portion of the swirl gas chamber.

Abstract: In some aspects, a plasma torch head for a plasma arc torch can include ports disposed within a base portion that are configured to receive fluids and electrical signals from a plasma torch lead via a plasma torch receptacle, the ports being shaped to align the torch head and the plasma torch receptacle during connection and including: a central coolant supply port to convey a liquid coolant to the torch head, the central coolant supply port extending a length to primarily align the plasma torch head with the torch receptacle, the central coolant supply port further including a flat surface shaped to secondarily align the torch head with the torch receptacle upon mating engagement, and an ohmic contact connector defining a tertiary alignment feature; and a connector disposed about the base portion shaped to engage with and couple to the torch receptacle.

Abstract: A connector component configured for coupling a consumable component to a plasma arc torch is provided. The connector component comprises a body having a proximal end and a distal end disposed along and defining a longitudinal axis. The connector component includes at least two engagement regions disposed radially about the longitudinal axis on a surface of the body. Each engagement region includes at least one engagement feature disposed on the surface of the body. The connector component also includes at least two free regions disposed radially about the longitudinal axis on the surface of the body. Each free region is radially located between a pair of the engagement regions and characterized by an absence of the engagement feature.

Abstract: The invention features methods and apparatuses for regulating a shielding liquid in a plasma torch. A liquid-injection shield for a plasma torch includes a body having an exterior surface and an interior surface and a liquid injection regulation component circumferentially disposed within and in direct contact with the interior surface of the body. The liquid injection regulation component and the interior surface of the body define a chamber. The liquid injection regulation component also defines a first set of ports sized to regulate a liquid entering the chamber and a second set of ports oriented to distribute a fluid exiting the chamber.

Abstract: A shield for a plasma arc torch is configured to protect consumable components of the plasma arc torch from splattering molten metal. The shield includes a generally conical unitary body defining (i) an interior surface to form a gas flow path with an outer surface of an adjacent nozzle of the plasma arc torch, and (ii) an exterior surface. The body includes (i) a distal first portion defining an exit orifice; and (ii) a proximal second portion formed of a flange sharing a common surface with the distal first portion. The shield also includes a seal assembly disposed on the common surface to retain the liquid coolant flow along the proximal second portion.

Abstract: A plasma cutting system is provided. The system includes a torch tip having a proximal end and a distal end defining a longitudinal axis extending therethrough. The torch tip includes a plasma plenum and a plasma arc exit orifice located at the distal end of the torch tip. The system includes a lead having a distal end configured for connection to the proximal end of the torch tip. The system also includes an atmospheric vent port disposed between the plasma arc exit orifice and the distal end of the lead. The system further includes a conduit fluidly connecting the plasma plenum and the atmospheric vent port.

Abstract: The invention features methods and apparatuses for liquid cooling a plasma arc torch. An electrode is provided including a body having a longitudinal axis defining a first end, a second end, and a middle portion. The electrode includes a first sealing element disposed on an exterior of the body near the first end; a second sealing element disposed on the exterior of the body located in the middle portion, the second sealing element configured to provide a first gas seal to a swirl gas chamber and defining a portion of the swirl gas chamber; and a third sealing element disposed on the exterior of the body, the third sealing element located between the second sealing element and the second end, the third sealing element configured to provide a second gas seal to the swirl gas chamber and defining a portion of the swirl gas chamber.

Abstract: In some aspects, methods for limiting damage to a plasma arc torch body resulting from a consumable failure within the torch can include determining a specified conductivity parameter set point of a current to be provided to the plasma arc torch for a material processing operation; measuring a detected conductivity parameter of plasma arc current being provided to the plasma torch to perform the material processing operation; comparing the specified conductivity parameter set point to the detected conductivity parameter of plasma arc current and calculating an error term signal; and based on a determination that the error term signal exceeds a threshold amount, initiating a plasma arc shut down sequence to extinguish the plasma arc to limit damage to the plasma arc torch body.

Abstract: The invention features methods and apparatuses for regulating a shielding liquid in a plasma torch. A liquid-injection shield for a plasma torch includes a body having an exterior surface and an interior surface and a liquid injection regulation component circumferentially disposed within and in direct contact with the interior surface of the body. The liquid injection regulation component and the interior surface of the body define a chamber. The liquid injection regulation component also defines a first set of ports sized to regulate a liquid entering the chamber and a second set of ports oriented to distribute a fluid exiting the chamber.

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 component for a plasma arc torch includes a body portion, a tapered surface on the body portion, the tapered surface including a compressible member that provides a disengagement force relative to the body portion, and an axially disposed surface on the body portion for coupling a mating surface on an adjacent structure of the torch. The component can be a nozzle and/or an electrode.