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.

In some aspects, methods for providing a uniform shield gas flow for an air-cooled plasma arc torch can include supplying a shield gas to a shield gas flow channel defined by an exterior surface of a nozzle and an interior surface of a shield; flowing the shield gas along the shield gas flow channel; reversing the flow of the shield gas along the shield gas flow channel using a recombination region, the recombination region comprising at least one flow reversing member; and flowing the shield gas from the mixing region to an exit orifice of the shield, thereby producing a substantially uniform shield gas flow at the exit orifice.

A liquid cooled shield assembly for a plasma arc torch includes an inner cap and a shield. The inner cap includes a substantially hollow body having a proximal end and a distal end that define a longitudinal axis, the distal end including an annular portion about the longitudinal axis. The inner cap also includes a liquid passage defined, at least in part, by an interior surface of the body, the liquid passage including a first set of ports in the annular portion, the first set of ports extending between an interior portion of the body and an exterior portion of the body to convey a liquid therethrough. The shield at least partially surrounds the inner cap and has a liquid impingement region on an interior surface of the shield adjacent to the first set of ports, the liquid impingement region for receiving the cooling liquid.

A torch head for a liquid-cooled plasma arc torch is provided. The torch head includes a torch body and a torch insulator, coupled to the torch body, having a substantially non-conductive insulator body. The torch insulator includes (i) a first liquid coolant channel, disposed within the insulator body, configured to conduct a fluid flow from the torch head into a consumable cartridge along a first preexisting flow path, (ii) a first liquid return channel, disposed within the insulator body, configured to return at least a portion of the fluid flow from the cartridge to the torch head along the first preexisting flow path, and (iii) a gas channel, disposed within the insulator body, configured to conduct a first gas flow from the torch head to the cartridge along a second preexisting flow path. The first and second preexisting flow paths are fluidly isolated from each other.

A nozzle for a plasma arc torch has a longitudinal nozzle axis, a nozzle orifice with a generally cylindrical orifice sidewall centered on the nozzle axis, and an orifice inlet that is formed as a surface of rotation about the nozzle axis; a gas-directing surface may also be provided. The orifice inlet has a variably-curved surface generated by rotating a variably-curved element about the nozzle axis, where the variably-curved element can be a portion of an ellipse, parabola, or hyperbola, and can join to the orifice sidewall and to the gas-directing surface, if provided. Both the orifice sidewall and the gas directing surface can each join the variably-curved element in a substantially tangential manner. Using an elliptical contour for the orifice inlet was found to increase stability for the plasma arc, providing improved cut quality and faster cutting speed for the torch.

A nozzle for a liquid-cooled plasma arc torch is provided. The nozzle includes a thermally conductive body having a distal end, a proximal end, and a longitudinal axis extending therethrough. The nozzle also includes a plasma arc exit orifice at the distal end of the thermally conductive body. The nozzle additionally includes a cooling waist located circumferentially about an exterior surface of the thermally conductive body. The cooling waist includes a liquid inlet slope, a liquid outlet slope and a heat exchange region between the liquid inlet slope and the liquid outlet slope. The heat exchange region extends substantially parallel to the longitudinal axis, and the liquid inlet slope and the liquid outlet slope are oriented generally perpendicular to the longitudinal axis.

A plasma processing system includes a torch having a consumable. A gas pressure regulator includes an input pressure sensor configured to sense an input pressure to the gas pressure regulator. A gas conduit supplies gas from the gas pressure regulator to the torch. A controller is operatively connected to the gas pressure regulator to receive an input pressure signal from the input pressure sensor and to provide a control signal to the gas pressure regulator to control operations of the gas pressure regulator and set an output pressure of the gas pressure regulator. The controller is configured to identify the consumable based on both of the input pressure to the gas pressure regulator and the control signal provided to the gas pressure regulator.

A plasma gas swirl ring for a liquid cooled plasma arc torch is provided. The swirl ring comprises a substantially hollow body having a distal end, a proximal end, an interior region defined by an interior surface, and an exterior surface. The interior region of the body is configured to receive an electrode of the plasma arc torch. The swirl ring comprises a first opening disposed within a portion of the proximal end of the body, a second opening disposed about a central portion of the body, and a third opening comprising at least one swirling port disposed within a portion of the distal end of the body. The third opening is configured to provide a swirling flow of the plasma gas about the electrode at the distal end of the body.

A torch head for a liquid-cooled plasma arc torch is provided. The torch head includes a torch body and a torch insulator, coupled to the torch body, having a substantially non-conductive insulator body. The torch insulator includes (i) a first liquid coolant channel, disposed within the insulator body, configured to conduct a fluid flow from the torch head into a consumable cartridge along a first preexisting flow path, (ii) a first liquid return channel, disposed within the insulator body, configured to return at least a portion of the fluid flow from the cartridge to the torch head along the first preexisting flow path, and (iii) a gas channel, disposed within the insulator body, configured to conduct a first gas flow from the torch head to the cartridge along a second preexisting flow path. The first and second preexisting flow paths are fluidly isolated from each other.

A liquid-cooled consumable cartridge for a plasma arc torch is provided. The cartridge includes (i) an electrode, (ii) a swirl ring with a first outer retaining feature and a second outer retaining feature on an exterior surface, where the electrode is secured to the swirl ring, and (iii) a nozzle with an inner retaining feature on an interior surface, where the inner retaining feature of the nozzle is mated with the first outer retaining feature of the swirl ring. The cartridge also includes a cartridge frame with an inner retaining feature on an interior surface and an outer retaining feature on an exterior surface. The inner retaining feature of the cartridge frame is mated with the second outer retaining feature of the swirl ring. The cartridge further includes a shield with an inner retaining feature on an interior surface mated with the outer retaining feature of the cartridge frame.