A connection system connects a plasma torch to a generator to allow the passage of electric current, the passage of an operating fluid, and of one or more control signals between the generator and the torch. The system includes a first connector and a second connector that are removably connected to each other. The first connector includes a first current-carrying terminal and the second connector having a second current-carrying terminal. The current-carrying terminals are suited to be mutually connected to each other. The first connector includes one or more electric terminals. The second connector includes one or more electric terminals, the connectors being suited to be mutually connected to each other. In the first connector, the electric terminals are movable with respect to the first terminal.

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, contact members to connect plasma torch leads to plasma cutting systems can include: a base portion; a set of ports within the base portion that include: a coolant supply port to convey a liquid coolant from the cutting system to a plasma arc torch connected to the contact member by the torch lead, a coolant return port: i) to convey return liquid coolant from the torch to the cutting system, and ii) to convey an operational current from the cutting system to the torch, at least one gas supply port to convey processing gases to the torch, and an ohmic contact connector; and a connector to couple the base portion to the cutting system and connect each of the ports and electrical connectors to respective complementary connections of the cutting system upon coupling to the cutting system.

Disclosed is a demountable tube for a plasma torch assembly, such as an ICP torch assembly. The tube includes an open tubular body for radially surrounding a plasma within the tubular body. The tubular body may comprise a wall; and a mounting feature projecting from the tubular body for at least one of: (i) controlling alignment of the tubular body with respect to a mounting portion of the torch assembly, and (ii) releasably securing the tubular body to a portion of the torch assembly. The tubular body may also have a transmission zone that is partially devoid of said wall and includes at least one hole through said wall. The tube may be opaque. A plasma torch and ICP spectroscopy system are also disclosed.

A torch tip assembly of a plasma arc torch is provided for delivering a diffused stream of plasma arc in a gouging operation. The assembly comprises a nozzle including a nozzle body defining a central longitudinal axis extending between a proximal end and a distal end. A nozzle exit orifice of the nozzle body defines at least a bore for conducting the plasma arc therethrough. The assembly also comprises a counter bore feature, disposed relative to the distal end the nozzle body, fluidly connected to the bore and located distally relative to the bore. At least one of the bore or the counter bore feature has a non-circular cross-sectional shape in a plane perpendicular to the longitudinal axis. The non-circular cross-sectional shape is configured to enable a second non-circular cross-sectional shape in the plasma arc that diffuses the plasma arc.

Provided herein is a quick disconnect torch handle for use in a plasma arc system. In one approach, the plasma arc system includes a lead having a first end connected to a power source and a second end connected to a torch handle. The quick disconnect is located at a proximal end of the torch handle, and may include at least one signal connection, a pilot connection, a fluid connection, and a main power connection. The fluid and power connection may be formed by a connection between a main power socket and a conductive conduit. Specifically, the main power socket includes a conductive spring and an O-ring encircling an interior bore thereof. Removal of the conductive conduit from the main power socket causes the fluid connection to break between the O-ring and the conductive conduit, and then the power connection to break between the conductive spring and the conductive conduit.

Provided herein is a quick disconnect torch handle for use in a plasma arc system. In one approach, the plasma arc system includes a lead having a first end connected to a power source and a second end connected to a torch handle. The quick disconnect is located at a proximal end of the torch handle, and may include at least one signal connection, a pilot connection, a fluid connection, and a main power connection. The fluid and power connection may be formed by a connection between a main power socket and a conductive conduit. Specifically, the main power socket includes a conductive spring and an O-ring encircling an interior bore thereof. Removal of the conductive conduit from the main power socket causes the fluid connection to break between the O-ring and the conductive conduit, and then the power connection to break between the conductive spring and the conductive conduit.

An electrode-supporting assembly for a contact-start plasma arc torch has an insulator that partially houses an electrode, and employs a spring-loaded plunger to bias the electrode to a forward position. The spring is engaged between the plunger and a contact element attached to the insulator, and may conduct electrical current to the electrode. The plunger, spring, and contact element are retained in the insulator when the torch is opened to replace the electrode, which is a consumable part. The electrode and the plunger have axially-engagable mating surfaces to assure good thermal and electrical conductivity therebetween. Conductivity can be further enhanced by forming the plunger of silver or a silver-bearing alloy. In some embodiments, a passage through the insulator is partitioned into forward and rear chambers, with the plunger, spring, and contact element trapped in the rear chamber.

A lead connector is provided for connecting a plasma torch lead of a plasma arc torch to a power supply of a plasma cutting system. The lead connector includes a base portion, a central conduit disposed in the base portion, where the central conduit is configured to carry a gas and a torch current to the plasma arc torch, and multiple pins disposed radially about a center of the central conduit. The pins are located at a radius of between about 0.4 inches and about 0.65 inches from the center of the central conduit on a radial plane of the base portion. The pins include one or more pilot carrying pins and one or more control signal pins located from about 27 degrees to about 64 degrees and from about 120 degrees to about 170 degrees, respectively, about the center of the central conduit on the radial plane.

An inductively coupled plasma (ICP) torch is described that includes a tapered outer end. A system embodiment includes, but is not limited to, a tubular sample injector configured to receive an aerosolized sample in an interior defined by walls of the tubular sample injector; an inner tube surrounding at least a portion of the tubular sample injector to form a first annular space between the inner tube and the walls of the tubular sample injector, the inner tube defining at least one inlet port for introduction of an auxiliary gas into the first annular space; and an outer tube surrounding at least a portion of the inner tube to form a second annular space, the outer tube defining at least one inlet port for introduction of a cooling gas into the second annular space, the outer tube having a flared region at an outlet of the outer tube.