Abstract: A plasma torch is provided having a movable member carrying an electrode and movable along a tubular member bore having a nozzle at one end. A piston member engaged with the movable member moves the electrode between inoperable and operable positions within the bore, the movable member being biased outwardly of the one end of the bore. A first sealing member engaged with the piston member allows a fluid flow into the bore to act on the piston member to move the electrode to the operable position when the nozzle/electrode is engaged with the tubular member. A second sealing member, engaged with the bore, engages the piston member when the nozzle/electrode is removed. The fluid flow enters the bore between the sealing members, the second sealing member thus preventing torch operation when the nozzle/electrode is removed by preventing the fluid flow from acting on the piston.

Abstract: A modular inductively coupled plasma torch assembly is described. A rear connector unit is positioned and detachably held at a rear end of a tubular plasma chamber to provide a flow of material into it. Detachable connector units are positioned on opposite ends of a tubular jacket, and hold the tubular plasma chamber concentrically within the tubular jacket so as to define an annular chamber between the two tubes. An inductor coil is disposed concentrically around the tubular jacket and energized so as to generate plasma from the material flowing in the tubular plasma chamber. To cool the tubular plasma chamber, coolant flows through the annular chamber using inlet and outlet ports in the detachable connector units for such flow of coolant.

Abstract: A modular plasma arc torch is provided that comprises a torch head and a torch lead, and a quick disconnect that is operatively engaged between the torch head and the torch lead. Accordingly, the torch head and torch lead may be quickly assembled and disassembled through the use of the quick disconnect. Further, the modular plasma arc torch also comprises a gas control device disposed within the plasma arc torch, which is operatively engaged between the torch head and the torch lead through the use of the quick disconnect according to the present invention. In addition, the quick disconnect may be used to connect a wide range of torch components within a plasma arc torch, thereby providing a reconfigurable plasma arc torch. Moreover, the quick disconnect according to the present invention conducts both gas and electric power from a power supply to the torch head for operation of the plasma arc torch.

Abstract: A method and apparatus for a gas-cooled plasma arc torch. Components of the torch can include an electrode, nozzle and a shield, each of which can be gas-cooled. The nozzle can be disposed relative to the electrode and can include a generally hollow conductive body and a cooling gas flow channel defined by at least one fin disposed about an exterior surface of the body, the body providing a thermal conductive path that transfers heat between the nozzle to the cooling gas flow channel during operation of the torch. The shield can be disposed relative to the nozzle and can include a generally hollow conductive body and a cooling gas flow channel defined by at least one fin disposed about an exterior surface of the body, the body providing a thermal conductive path that transfers heat between the shield to the cooling gas flow channel during operation of the torch.

Abstract: A process for increasing the surface tension (“wettability”) of a silicone element crosslinked by polyaddition from a liquid composition containing one or more ?,?-dimethylvinylpolydimethylsiloxanes (PDMS), one or more poly(dimethyl)(methylhydrogenosiloxy)-?,?-dimethylhydrogenosiloxanes, and a platinum crosslinking catalyst. The silicone surface is treated with a homogeneous atmospheric plasma using a plasma spraying apparatus having a rotating head with one or more plasma nozzles that are offset relative to the axis of rotation, each one being capable of generating a plasma jet whose axis is parallel to said axis of rotation. The articles to which the invention relate include composites of flexible substrate (e.g. textile)/silicone coating. Application: adhesive bonding of silicone surfaces crosslinked by ?Si—H/?Si-vinyl polyaddition.

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 plasma processing apparatus for powder, and a plasma processing method of powder, in which a powder supply nozzle is provided to supply a powder material into plasma flame generated inside a high-frequency coil, the powder supply nozzle arranged substantially radially centrally of the high-frequency coil comprises a revolving flow forming device, for example, a spiral-shaped plate, to cause a carrier gas and the powder material to form therein a revolving flow with an axis thereof directed axially of the high-frequency coil, and the revolving flow is discharged from an outlet at an end of the nozzle. More preferably, a transition space is provided between the outlet at the end of the nozzle and the revolving flow forming device, and the outlet at the end of the nozzle is made small in diameter.

Abstract: The present invention provides a modular anode support member for a plasma spray gun including an outer sleeve, an inner sleeve, and a coolant tube connectable to the outer sleeve. The outer sleeve having a cylindrical sidewall defining a central opening through a length thereof for receiving the inner sleeve. The outer sleeve including a mounting member for mounting the outer sleeve and an associated spray gun to a spray gun manipulator. The inner sleeve for receiving an anode housing is removably disposed in the central opening of the outer sleeve and includes forward and rearward portions defined by a stepped central bore through a length thereof. The forward portion for receiving an anode housing therein, the rearward portion for carrying coolant to and from the anode housing. Alignment means are provided for fixing the relative position of the inner sleeve and outer sleeve in assembly.

Abstract: A component for use in a plasma arc torch is provided that includes a continuously contoured surface extending along the component that directs a flow of shield gas at a predetermined angle to result in a specific pierce or cut location on a workpiece. In one form, the component is a shield cap that includes an exit orifice extending through a central portion of the shield cap, the exit orifice defining an inlet portion and an outlet portion, and a continuously contoured surface extending between the inlet portion and the outlet portion. The continuously contoured surfaces may be convergent, divergent, or a combination of convergent and divergent according to the principles of the present disclosure. Additionally, the shield cap may comprise a single, unitary piece or alternately a plurality of pieces or components.

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: To protect the collimator of a transferred plasma arc torch from premature failure due to corrosion, an anti-corrosive covering is applied on the exposed face surface and a portion of the inner exit bore of the collimator. The specification describes several methods for producing the collimator for a plasma torch having an anti-corrosive coating or cladding on the exposed surfaces thereof, including electroplating, electroless plating, flame spraying, plasma spraying, plasma transferred arc, hot isostatic pressing and explosive cladding.

Abstract: A plasma jet electrode device includes an orientation base, a ceramic pipe, a round plate having a plurality of tilted through holes thereon and a high-voltage metal electrode. A dielectric discharging plasma area is formed between the high-voltage metal electrode and the ceramic pipe. The plasma jet electrode device further has a rotating base, a bottom plate, and a grounding electrode. A low-temperature non-equilibrium plasma area is formed between the grounding electrode and the high-voltage metal electrode. The round plate has a spray head praying low-temperature non-equilibrium plasma. The plasma treatment area is increased, and the uniformity is improved. The present plasma jet electrode system has a frame for fixing at least one plasma jet electrode device. It evidently increases the effective plasma treatment area. The system can also provide additional functions of cooling, guiding, plating and etching, etc.

Abstract: Vented shield systems for plasma arc torches are provided that comprise a shield cup body defining a distal end portion, a vented retainer secured to the distal end portion of the shield cup body, and a shield cap secured to the vented retainer. The vented retainer defines at least one vent passageway that directs a flow of secondary gas inward toward the shield cap, and the vented shield system blocks at least a portion of molten metal from contacting components, such as a tip or nozzle, of the plasma arc torch. The shield cap may comprise a mechanized cap, a drag cap, a gouging cap, or a deflector cap, among others. Accordingly, various shield caps may be employed without removal or replacement of the vented retainer. The same vented retainer may be used throughout a variety of plasma arc torch applications.

Abstract: A vortex generator uses a single piece to generate the vortex and hold the electrode. The single piece may be a non-conductive material such as a ceramic. The vortex generator may use threads to hold the electrode. The threads and the means for generating the vortex may be bored into the base material of the vortex generator before the base material is hardened.

Abstract: An improved collimator for a plasma arc torch consists of an annular holder member and an insert member. The insert member includes a tubular stem portion ending in an integrally formed, radially extending face plate. When the stem portion is fitted into the central bore of the holder member with a predetermined clearance fit therebetween, a cooling water passage is created. The improved collimator is characterized by the absence of any welds between the holder member and the insert member that would be exposed to conductive gases given off during use of the plasma arc torch and a lesser resistance to cooling water flow than prior art collimator designs.

Abstract: Apparatus and methods for thermally processing a workpiece include directing a plasma arc to the workpiece and using a dielectric shield or dielectric coating to protect a forward portion (e.g., a torch head) of a plasma arc torch. The dielectric shield or dielectric coating covers a nozzle disposed within the torch head and protects the nozzle from the effects of slag and double arcing. The shield also improves operator visibility due to the spatial relationship between the dielectric shield and the nozzle.

Abstract: A plasma jet electrode device includes an orientation base, a ceramic pipe, a round plate having a plurality of tilted through holes thereon and a high-voltage metal electrode. A dielectric discharging plasma area is formed between the high-voltage metal electrode and the ceramic pipe. The plasma jet electrode device further has a rotating base, a bottom plate, and a grounding electrode. A low-temperature non-equilibrium plasma area is formed between the grounding electrode and the high-voltage metal electrode. The round plate has a spray head praying low-temperature non-equilibrium plasma. The plasma treatment area is increased, and the uniformity is improved. The present plasma jet electrode system has a frame for fixing at least one plasma jet electrode device. It evidently increases the effective plasma treatment area. The system can also provide additional functions of cooling, guiding, plating and etching, etc.

Abstract: A plasma arc torch and methods for assembling and disassembling a plasma arc torch wherein a plurality of front end parts of the torch form a unit that is removable from the torch in a single operation to gain access to the electrode. The unit can then be reinstalled in the torch in a single operation after replacement of the electrode. An assembly fixture is employed to facilitate pre-assembly of the unit of front end parts prior to installation of the unit in a torch.

Abstract: The invention relates to a protective cap for at least one contact pipe of a welding torch, the pipe or pipes having a respective bore for guiding and contacting a respective welding rod that is fed through the pipe or pipes. The cap comprises a housing consisting of or coated with a poor electrically conductive material, for receiving the contact pipe and a bore, which allows the welding rod to emerge. The aim of the invention is to increase the service life of a contact pipe or a welding torch comprising at least one contact pipe of this type. To achieve this, at least two openings are provided in the housing for receiving at least two contact pipes and each opening is connected to one respective bore in the housing for receiving at least two contact pipes and each opening is connected to one respective bore in the housing. Each bore is positioned in such a way that it corresponds with the course of the welding rod in the contact pipe, once the protective cap has been mounted.

Abstract: A method is provided for purifying gases, particularly gases contaminated by environmentally harmful substances, by way of plasma discharge. The gas to be purified is guided through a thermal plasma, which is generated by electrodeless ignition of a process gas, so that, by way of the thermal plasma, the harmful substances contained in the gas to be purified are converted to environmentally neutral, fully oxidized substances.

Abstract: A coolant tube and electrode are adapted to mate with each other to align the tube relative to the electrode during operation of the torch. Improved alignment ensures an adequate flow of coolant along an interior surface of the electrode. In one aspect, an elongated body of the coolant tube has a surface adapted to mate with the electrode. In another aspect, an elongated body of the electrode has a surface adapted to mate with the coolant tube. The surfaces of the tube and electrode may, for example, be flanges, tapered surfaces, contours, or steps.

Abstract: A plasma jet system includes a housing with an opening. A plasma generator is coupled to ionize a fluid in the housing. An electromagnetic accelerator is coupled to generate an electric field that accelerates ionized fluid in the housing toward the opening. A controller can modulate the frequency of the electric field to cause the ionized fluid to form a plasma vortex flow through the opening. A magnetic field is applied normal to the direction of the plasma vortex flow to mitigate the momentum of the electrons. The electrons slowed by the magnetic field can be collected and conducted to a location where they are re-inserted into the plasma vortex flow to maintain charge neutrality.

Abstract: A torch cable in which both the electrical connection and the pneumatic connection can be made concurrently in one motion by coupling the end of the torch cable to the exterior of the supply unit. The coupling further includes a quick disconnect feature. The torch cable coupling is simple and inexpensive, using standard off-the-shelf components. The end of the cable comprises various components that are overmolded to form an electrically insulative body, e.g., made of urethane rubber compound. This molded body incorporates strain relief, is water resistant, protects the electrical plug, and stabilizes the electrical contacts. Gas, power and control are combined in one assembly. The pneumatic quick disconnect coupling is used as a latching mechanism for the entire assembly. The torch cable can be disconnected from the supply unit by simply releasing the quick disconnect coupling and then pulling the end of the torch cable away from the supply unit.

Abstract: Systems and methods for generating relatively cool microwave plasma. The present invention provides a microwave plasma nozzle that includes a gas flow tube through which a gas flows, and a rod-shaped conductor that is disposed in the gas flow tube and has a tapered tip near the outlet of the gas flow tube. A portion of the rod-shaped conductor extends into a microwave cavity to receive microwaves passing in the cavity. These received microwaves are focused at the tapered tip to heat the gas into plasma. The microwave plasma nozzle also includes a vortex guide between the rod-shaped conductor and the gas flow tube imparting a helical shaped flow direction around the rod-shaped conductor to the gas flowing through the tube. The microwave plasma nozzle further includes a mechanism for electronically exciting the gas and a shielding mechanism for reducing a microwave power loss through the gas flow tube.

Abstract: A tip gas distributor is provided that preferably comprises a plurality of swirl holes and a plurality of secondary gas holes, wherein the swirl holes direct a plasma gas to generate a plasma stream, and the secondary gas holes direct a secondary gas to stabilize the plasma stream. Additionally, a tip gas distributor is provided that comprises swirl passages and secondary gas passages formed between the tip gas distributor and an adjacent component to generate and stabilize the plasma stream. Further, methods of generating and stabilizing the plasma stream are provided through the use of the swirl holes and passages, along with the secondary gas holes and passages.

Abstract: A plasma generation system that is powered with an alternating current power source has been developed. The system includes a plasma generator that heats gas to a high temperature to form plasma. The gas is heated by passing through an electrical arc generated by electrodes. The gas is fed to the generator by a feed system comprising a plurality pneumatic feed devices that supply the plasma-forming gas. The plasma generator is powered by an alternating current power source.

Abstract: The invention relates to an electric arc wire burner for spraying an electric arc, comprising at least two burner tubes (3) for feeding electrodes which are embodied in the form of wire (5). Said electrodes are guided through the burner tube (3) in the direction of the surface of the object which is to be coated. The wire (5) is guided by a deflection device (7) comprising a number of rotationally mounted guiding elements and/or sliding elements (8) and the wire (5) is deformed in an elastic area.

Abstract: A metering system and associated method for supplying gas to a torch are provided. The metering system includes a controller that is configured to adjust a pressure regulator according to the pressure and flow rate of the gas delivered to the torch. For example, the torch can be a plasma arc torch that has an electrode positioned in a nozzle and operates in a working mode by providing an arc from the electrode to a workpiece. In a first mode of operation, the metering system can provide a gas to the torch by adjusting the pressure regulator according to the pressure downstream of the pressure regulator. In a second mode of operation, the metering system can provide adjust the pressure regulator according to the flow rate of the gas through a flow transducer in series with the pressure regulator.

Abstract: A method and apparatus for indicating a temperature of a torch consumable is disclosed. The invention includes a shielding cup constructed to be attached to a torch having a coating which indicates a temperature of the shielding cup during a welding/cutting process. Preferably, the coating indicates to a user when the temperature of the torch is beyond a preferred operating range thereby preventing excessive wear of the consumables associated with overheating.

Abstract: A threaded connection for an electrode holder and an electrode in a plasma arc torch is provided. The threaded connection has relatively low height, and the engaged portion of a male threaded portion of the electrode and a female threaded portion of the electrode holder are positioned at least partially within a nozzle chamber. In one inventive aspect, the nominal pitch diameter of the electrode is less than the minor diameter of the electrode. In another, the width of the root area of the electrode thread is wider than the width of the root area of the electrode holder thread by at least about 35%. The width of the root area of the electrode is at least about 15% wider than the width of the crest portion of the electrode. As such, the less consumable of the two parts, the electrode holder, is provided with a thread that is less likely to be worn and damaged. In one particular embodiment, the crest profile of the electrode is that of a Stub Acme thread separated by a larger root profile.

Abstract: A plasma arc torch is provided that comprises a set of torch consumable components secured to a torch head, wherein a supply of cooling fluid flows coaxially through the torch to cool torch components and a supply of plasma gas and secondary gas flows through the torch to generate and stabilize a plasma stream for operations such as cutting workpieces. The torch consumable components, in part, comprise an electrode and a tip that include a variety of configurations for improved cooling, electrical contact, and attachment to adjacent torch components. Further, a consumables cartridge is provided for ease of use and replacement of the torch consumable components. Additionally, methods of operating the plasma arc torch at relatively high current levels are also provided by the present invention.

Abstract: A trigger system for operating a plasma arc torch is provided that comprises a selector that operates between at least a first operating position and a second operating position, wherein the first operating position operates the plasma arc torch in a first mode to deliver gas to the plasma arc torch, and the second operating position operates the plasma arc torch in a second mode to deliver the gas and electric power to the plasma arc torch. Further, the selector comprises a neutral position that selects a neutral mode in which delivery of gas and electric power to the plasma arc torch is inhibited. The selector is preferably disposed within a housing of the plasma arc torch and is slidably operable between the first operating position, the second operating position, and the neutral position.

Abstract: A coolant tube and electrode are adapted to mate with each other to align the tube relative to the electrode during operation of the torch. Improved alignment ensures an adequate flow of coolant along an interior surface of the electrode. In one aspect, an elongated body of the coolant tube has a surface adapted to mate with the electrode. In another aspect, an elongated body of the electrode has a surface adapted to mate with the coolant tube. The surfaces of the tube and electrode may, for example, be flanges, tapered surfaces, contours, or steps.

Abstract: A plasma arc torch is provided that comprises a set of torch consumable components secured to a torch head, wherein a supply of cooling fluid flows coaxially through the torch to cool torch components and a supply of plasma gas and secondary gas flows through the torch to generate and stabilize a plasma stream for operations such as cutting workpieces. The torch consumable components, in part, comprise an electrode and a tip that include a variety of configurations for improved cooling, electrical contact, and attachment to adjacent torch components. Further, a consumables cartridge is provided for ease of use and replacement of the torch consumable components. Additionally, methods of operating the plasma arc torch at relatively high current levels are also provided by the present invention.

Abstract: A method and system to obtain a high power density plasma to efficiently generate high concentrations of plasma downstream from one or more plasma sources. A first embodiment of the invention involves a method to provide an improved power density for dissociating one or more gases to create plasma. A second embodiment of the invention involves a method to provide multiple chambers for dissociating one or more gases to create plasma. A third embodiment involves an apparatus using a constriction in a discharge chamber containing one or more gases, to provide an improved power density for dissociating one or more gases to create plasma. A fourth embodiment involves an apparatus using a constriction in multiple discharge chambers containing one or more gases, to provide an improved power density for dissociating one or more gases to create plasma.

Abstract: Plasma torch (8; 10) of improved performances, comprising: an electrode (13) provided with a respective electrode head (18; 37); a nozzle (14); and an outside jacket (26), there being formed a first cooling circuit (20, 21) of a coolant for the electrode head (18; 37) having an end passage (22), said head being characterised in that it comprises a device (25) for disposing of the electrode heat, located inside of the first cooling circuit.

Abstract: A plasma arc torch is provided that comprises a set of torch consumable components secured to a torch head, wherein a supply of cooling fluid flows coaxially through the torch to cool torch components and a supply of plasma gas and secondary gas flows through the torch to generate and stabilize a plasma stream for operations such as cutting workpieces. The torch consumable components, in part, comprise an electrode and a tip that include a variety of configurations for improved cooling, electrical contact, and attachment to adjacent torch components. Further, a consumables cartridge is provided for ease of use and replacement of the torch consumable components. Additionally, methods of operating the plasma arc torch at relatively high current levels are also provided by the present invention.

Abstract: Electrode and nozzle that seat within a retaining member and in two different seating locations relative to retaining member. The electrode and nozzle each include an interwoven-double-start thread having two thread cuts, which start 180 degrees from one another as measured around the circumference of the electrode or nozzle. Further, the electrode, nozzle, and retaining member include mating frustum surfaces, which are configured and dimensioned so that the electrode and nozzle seat within the retaining member with less than one turn of the electrode and nozzle relative to the retaining member. Therefore, the electrode and nozzle may be quickly inserted in, and removed from, the retaining member.

Abstract: A plasma arc torch and method for improving the life of the consumable parts of the plasma arc torch, including the electrode, the tip and the shield cap. The method includes turbulating gas as it flows over the exposed surfaces of the electrode, tip and shield cap to increase turbulence in the hydrodynamic boundary layer of the gas flow, thereby enhancing convective heat transfer. The result of enhanced cooling is improved consumable parts life. For example, to increase the turbulence of the gas flow over the outer surface of the electrode, the plasma arc torch electrode has a roughened, or textured outer surface formed with dimples, axially extending grooves or spiraling grooves formed in the outer surface of the electrode. The inner and outer surfaces of the tip and the inner surface of the shield cap are similarly textured.

Abstract: Electrode and nozzle that seat within a retaining member and in two different seating locations relative to retaining member. The electrode and nozzle each include an interwoven-double-start thread having two thread cuts, which start 180 degrees from one another as measured around the circumference of the electrode or nozzle. Further, the electrode, nozzle, and retaining member include mating frustum surfaces, which are configured and dimensioned so that the electrode and nozzle seat within the retaining member with less than one turn of the electrode and nozzle relative to the retaining member. Therefore, the electrode and nozzle may be quickly inserted in, and removed from, the retaining member.

Abstract: A nozzle for a plasma arc cutting torch is provided with an electrically conductive, heat resistant insert, preferably tungsten or a tungsten alloy. As an alternative to the insert, the material can be coated on the entire inner surface of the nozzle. In either embodiment, the material also can be coated on the outer surface of the nozzle.

Abstract: A system for controlling gas flow from a gas source, through a gas conduit, and to a plasma arc torch during a transition from a cold flow when no arc is present to a hot flow when an arc is provided by the present invention. The system comprises a first solenoid in communication with the gas source, a second solenoid disposed proximate the plasma arc torch, and a bypass circuit in communication with the gas source and the second solenoid. The bypass circuit comprises a bypass solenoid that controls the gas pressure within the gas conduit to reduce gas flow fluctuations when transitioning from cold flow to hot flow. Additional gas control systems and methods are also provided that cause the gas pressure to be higher during cold flow, prior to arc ignition, which overcomes the rapid drop in flow that typically occurs during the transition to hot flow.

Abstract: A coolant tube and electrode are adapted to mate with each other to align the tube relative to the electrode during operation of the torch. Improved alignment ensures an adequate flow of coolant along an interior surface of the electrode. In one aspect, an elongated body of the coolant tube has a surface adapted to mate with the electrode. In another aspect, an elongated body of the electrode has a surface adapted to mate with the coolant tube. The surfaces of the tube and electrode may, for example, be flanges, tapered surfaces, contours, or steps.

Abstract: An inductively-coupled plasma torch capable of holding a capillary tube coaxially with an injector tube and conveying make-up gas smoothly is provided. The inductively-coupled plasma torch of the present invention includes a guide which is held near the end portion of the injector tube, and has a through hole for holding the capillary tube coaxially with the injector tube, and means for conveying make-up gas.

Abstract: A dual mode plasma arc torch is provided that preferably comprises a start cartridge disposed between an electrode and a tip. In one form, the start cartridge comprises an initiator that is in electrical contact with the electrode and that is resiliently biased into contact with the tip, such that when the plasma arc torch is in a contact start mode, the initiator is movable against the resilient bias to separate from the tip and establish a pilot arc between the initiator and the tip. Further, when the plasma arc torch is in a high frequency start mode, the start cartridge spaces the tip from the electrode such that a pilot arc is established between the electrode and the tip. In other forms, a contact start torch is provided that is operable under high frequency, and conversely, a high frequency start torch is provided that is operable under low voltage.

Abstract: A plasma processing apparatus capable of making an accurate lifetime assessment for each of plural consumable parts (the definition of “the consumable part” is an electrode and/or a nozzle) so that effective use of the consumable parts becomes possible leading to reduced running cost. In the plasma processing apparatus, a plasma arc is generated from a plasma torch composed of an electrode and a nozzle to perform plasma work on a workpiece. Such a plasma processing apparatus includes a plurality of consumable parts, each consumable part being an electrode and/or a nozzle, and further comprises a memory for storing consumption data on every consumable part, the consumption data being used for calculation of consumption; and a display unit for displaying consumption calculated by a CPU for selecting the consumption data corresponding to a consumable part in use.

Abstract: A main arc ignition method capable of extending lives of a plasma electrode and a nozzle. For this purpose, before or immediately after starting arc, a plasma torch is supplied with a plasma gas at least either at a lower flow rate or at lower gas pressure; the plasma gas is switched to a gas flow rate and gas pressure of a time of cutting a work, after pilot arc is ignited between an electrode and a nozzle, or after main arc is ignited between the electrode and the work; and when generation of the main arc between the electrode and the work is detected, a pilot current is interrupted promptly by a semiconductor switch which is interposed in series with a resistance, in a pilot current circuit that is connected to the nozzle and supplies the pilot current to the pilot arc.

Abstract: A plasma arc torch is provided that comprises torch head connections that are made between consumable components and a torch head independent of rotational alignment of the consumable components. Accordingly, connections for the flow of a cooling fluid, plasma gas, and/or a secondary gas are made independent of rotational alignment. Additionally, electrical connections are also provided that are independent of rotational alignment of the various plasma arc torch components.

Abstract: Vented shield systems for plasma arc torches are provided that comprise a shield cup body defining a distal end portion, a vented retainer secured to the distal end portion of the shield cup body, and a shield cap secured to the vented retainer. The vented retainer defines at least one vent passageway that directs a flow of secondary gas inward toward the shield cap, and the vented shield system blocks at least a portion of molten metal from contacting components, such as a tip or nozzle, of the plasma arc torch. The shield cap may comprise a mechanized cap, a drag cap, a gouging cap, or a deflector cap, among others. Accordingly, various shield caps may be employed without removal or replacement of the vented retainer. The same vented retainer may be used throughout a variety of plasma arc torch applications.

Abstract: A contact start plasma arc torch is provided that comprises an electrode, a tip, and an initiator that is resiliently biased into contact with the tip, the initiator being movable against the resilient bias to separate from the tip and establish a pilot arc between the initiator and the tip. The initiator is disposed within a start cartridge, which preferably comprises a coil spring that biases the initiator into contact with the tip. The plasma arc torch further comprises a plurality of head vent holes to vent gas from within the start cartridge during operation of the torch. Additionally, the tip defines a plurality of swirl holes and secondary gas holes to generate and control a plasma stream that is subsequently blown from a central exit orifice in the tip.