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, contacting a proximal end of the electrode body, is used for imparting a separation force to the electrode body. The electrode body is adapted to overcome the separation force and engage a contact element of the torch when the torch is operated in a transferred arc mode.

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. The electrode and torch can include a contact element having a first surface in electrical communication with the power contact and a second surface characterized by (i) physical contact with the electrode body during transferred arc mode and (ii) absence of physical contact with the electrode body during initiation of a pilot arc.

Abstract: An electrode for a plasma arc torch includes a hollow elongated body having an open end and a closed end and an end face located at the closed end inside of the hollow elongated body. The end face has a center portion. A plurality of heat exchanging elements are in thermal communication with the end face. The heat exchanging elements have side walls defining an elongated channel between adjacent heat exchanging elements. The elongated channel extends radially from the center portion to an inner surface of the elongated body. The elongated channel provides a thermally conductive path that transfers sufficient heat from the elongated body to a cooling fluid during an operation of the plasma arc torch to prevent premature failure of the electrode.

Abstract: An electrode for a plasma arc torch includes a generally cylindrical elongated body formed of an electrically conductive material. The elongated body includes a proximal end that connects to a power supply and a distal end that receives an emissive element. The electrode can include a flange that is disposed about a surface relative to the distal end of the elongated body, extends radially from the surface of the elongated body, and is utilized to establish a uniform gas flow distribution of a plasma gas flow about the distal end of the elongated body. The electrode can include a contact element that is in electrical communication with the proximal end of the electrode. The contact element includes seating portion that has an outer width that is greater than the outermost diameter of the electrode body and is configured to position the contact element within the plasma arc torch.

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 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 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 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 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 electrode is provided for use in a plasma arc torch. The electrode includes a body having a forward portion, a middle portion and an aft portion. The forward portion includes an electrode tip comprising a conductive first material, wherein the electrode tip includes: 1) a pilot contact region for initiating a pilot arc across the nozzle and 2) an emitter. The middle portion comprises a second material and defines a proximal end for mating with the forward portion and a distal end for mating with the aft portion. The material density of the second material is at least half of the material density of the first material. The electrode also includes an electrically conductive path extending from the forward portion to the aft portion of the body.

Abstract: An improved electrode for use in a plasma arc torch. The electrode includes an electrode body, a cavity in a front face at a first end of the electrode body, and an insert disposed in the cavity. The first end of the electrode body is formed of high purity copper containing at least 99.81% copper. The insert has a first end and a second end and is formed of a high emissivity material. A diameter of the first end of the insert is less than a diameter of a second end of the insert. An electrode is compressed to retain the insert using radial compression. The invention also includes a method for forming the electrode, and a method of operation of an electrode in a plasma torch.

Abstract: A plasma arc torch system comprising a plasma arc torch is provided. The torch includes an electrode, a nozzle, a vent passage and a shield. The nozzle is spaced from the electrode to define a plasma chamber therebetween. The plasma chamber is configured to receive a plasma gas. The vent passage, disposed in the nozzle body, is configured to divert a portion of the plasma gas exiting the plasma chamber from a nozzle exit orifice. The shield is spaced from the nozzle to define a flow region therebetween. The flow region is configured to (i) receive a liquid and (ii) expel the liquid along with a plasma arc substantially surrounded by the liquid via a shield exit orifice.

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 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 nozzle, retaining cap, or shield 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, retaining cap, or shield 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 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 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 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 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 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.