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.

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.

The invention relates to an electrode for an especially gas-cooled plasma torch, in particular plasma cutting torch, the electrode comprising: an elongated electrode body with an open end and a closed end, the ends defining a longitudinal axis L, and an emission insert in the closed end, a cavity extending in the electrode body from the open end of the electrode body towards the closed end, the cavity fluidically communicating with the outer face of the electrode body which is radial with regard to the longitudinal axis, via at least one opening in its wall or in the front solid portion of the closed end. The invention further relates to a system consisting of said electrode and cooling tube, to a gas conducting unit, a plasma torch comprising same, a method for conducting gas in a plasma torch and a method for operating the plasma torch.

The invention relates to an electrode for an especially gas-cooled plasma torch, in particular plasma cutting torch, the electrode comprising: an elongated electrode body with an open end and a closed end, the ends defining a longitudinal axis L, and an emission insert in the closed end, a cavity extending in the electrode body from the open end of the electrode body towards the closed end, the cavity fluidically communicating with the outer face of the electrode body which is radial with regard to the longitudinal axis, via at least one opening in its wall or in the front solid portion of the closed end. The invention further relates to a system consisting of said electrode and cooling tube, to a gas conducting unit, a plasma torch comprising same, a method for conducting gas in a plasma torch and a method for operating the plasma torch.

A method for conducting gas in a gas-cooled plasma torch wherein the plasma torch has a plasma torch body which holds an electrode with an open end and a closed end. A cavity extends from the open end in the direction of the closed end, and which, with a spacing in an axial direction, holds a nozzle by means of a nozzle holder. The nozzle has a central opening with an upstream inlet end, into which the electrode projects, and with an outlet end with a nozzle bore and is surrounded by a nozzle cap and/or a nozzle protection cap. The plasma torch body has an opening for a gas feeder, which opening is fluidically connected to a cooling tube which projects into the open end of the electrode.

A method for conducting gas in a gas-cooled plasma torch wherein the plasma torch has a plasma torch body which holds an electrode with an open end and a closed end. A cavity extends from the open end in the direction of the closed end, and which, with a spacing in an axial direction, holds a nozzle by means of a nozzle holder. The nozzle has a central opening with an upstream inlet end, into which the electrode projects, and with an outlet end with a nozzle bore and is surrounded by a nozzle cap and/or a nozzle protection cap. The plasma torch body has an opening for a gas feeder, which opening is fluidically connected to a cooling tube which projects into the open end of the electrode.

In some aspects, electrodes can include a front portion shaped to matingly engage a nozzle of the plasma cutting system, the front portion having a first end comprising a plasma arc emitter disposed therein; and a rear portion thermally connected to a second end of the front portion, the rear portion shaped to slidingly engage with a complementary swirl ring of the plasma cutting system and including: an annular mating feature extending radially from a proximal end of the rear portion of the electrode to define a first annular width to interface with the swirl ring, the annular mating feature comprising a sealing member configured to form a dynamic seal with the swirl ring to inhibit a flow of a gas from a forward side of the annular mating feature to a rearward side of the annular mating feature.

In some aspects, electrodes can include a front portion shaped to matingly engage a nozzle of the plasma cutting system, the front portion having a first end comprising a plasma arc emitter disposed therein; and a rear portion thermally connected to a second end of the front portion, the rear portion shaped to slidingly engage with a complementary swirl ring of the plasma cutting system and including: an annular mating feature extending radially from a proximal end of the rear portion of the electrode to define a first annular width to interface with the swirl ring, the annular mating feature comprising a sealing member configured to form a dynamic seal with the swirl ring to inhibit a flow of a gas from a forward side of the annular mating feature to a rearward side of the annular mating feature.

In some aspects, methods for controlling a plasma arc in a plasma torch of a plasma cutting system in a low operating current mode can include: receiving, by a computing device within the plasma power supply, a command to begin a plasma processing operation; generating a pilot arc command to generate a pilot arc within the plasma torch, the generating of the pilot arc command including directing an electrical signal and a gas flow to the plasma torch, the electrical signal being configured to generate the pilot arc at a current having a first arc amperage magnitude; and generating an operational arc command to facilitate a transition from the pilot arc to an operational plasma arc, the generating of the operational arc command including adjusting the current directed to the plasma torch to be a second arc amperage magnitude that is lower than the first arc amperage magnitude.

In some aspects, methods for controlling a plasma arc in a plasma torch of a plasma cutting system in a low operating current mode can include: receiving, by a computing device within the plasma power supply, a command to begin a plasma processing operation; generating a pilot arc command to generate a pilot arc within the plasma torch, the generating of the pilot arc command including directing an electrical signal and a gas flow to the plasma torch, the electrical signal being configured to generate the pilot arc at a current having a first arc amperage magnitude; and generating an operational arc command to facilitate a transition from the pilot arc to an operational plasma arc, the generating of the operational arc command including adjusting the current directed to the plasma torch to be a second arc amperage magnitude that is lower than the first arc amperage magnitude.