Embodiments of the present invention include a plasma cutting torch and plasma cutting torch components, such as electrodes, cathodes, retainer caps, etc. having a unique physical features, including threads relationships. Embodiments include torch components having modified square thread with a specialized thread configuration including a particular relationship between thread crest and root, and included angles of thread sidewalls.

A consumable assembly for a plasma arc torch is provided, the consumable assembly including an electrode provided within an interior of a nozzle. The electrode may include a sidewall having one or more fluid passageways formed therethrough, an end wall extending from a distal end of the sidewall, and a central cavity defined by an inner surface of the sidewall and the end wall, the central cavity extending between distal and proximal ends of the electrode. The electrode may further include a heat removal element extending into the central cavity from the inner surface of the sidewall. In one embodiment, the consumable assembly includes a current and gas conduit at the proximal end of the electrode, the current and gas conduit including an interior bore radially aligned with the electrode for collectively delivering a plasma gas, a shield gas, and a vent gas into the central cavity of the electrode.

A center pipe is used in a plasma torch including a base portion and an electrode to supply cooling water into the electrode. The center pipe includes a pipe body and a contact piece. The pipe body has a tube-like shape with a cooling water channel therein. The pipe body is electrically conductive and configured to be electrically connected to an external power source via the base portion. The contact piece is arranged radially outside the pipe body at an intermediate position between a base end surface and a tip end surface of the pipe body. The contact piece is electrically conductive and energizes the electrode through contact with an internal circumferential surface of the electrode. The base end surface is disposed outside the electrode when the center pipe is inserted into the electrode. The pipe body is configured to be electrically connected to the electrode via the contact piece.

A gas conducting unit for a gas-cooled plasma cutting torch, wherein the gas-conducting unit is single-part or multi-part tubular or annular. The gas-conducting unit comprises a single-part or multi-part tubular or annular gas-conducting unit body with a longitudinal axis L1. In a wall of the gas-conducting unit body, there are situated at least one opening, which is inclined by an angle ? in a range of ?15? with respect to the longitudinal axis L1, and at least one second opening, which is inclined radially with respect to the longitudinal axis L1 or which, in a radial plane, is inclined at an angle ? in the range of ?30? from the radial to the longitudinal axis L1.

Disclosed is a plasma cutting torch copper-bodied electrode connecting the emitter cutter tip for plasma cutting torches with copper-bodied electrode body, prolonging the life and efficiency thereof with the surface increase of cooling surfaces, the electrode having an emitter cutter tip with surface increase channels formed with indentations/protrusions on the side surface thereof and surface increase channels formed with indentations/protrusions on the upper surface thereof and having a diameter enlarging in the form of a bowl from the outer diameter to the tip. A downstream electrode body carries the emitter cutter tip with a cavity on which this emitter cutter tip is secured, wherein by securing the emitter cutter tip on the cavity on the copper-bodied electrode body, the copper-bodied electrode with the liquid cooling system in the plasma torch is formed to cut the metallic piece.

A center pipe is used in a plasma torch for plasma cutting including a base portion and an electrode. The center pipe is inserted into the electrode and supplies cooling water into the electrode. The center pipe includes a pipe body and a contact piece. The pipe body is electrically connected to an electrical power source outside of the plasma torch via the base portion. The pipe body includes a cooling water channel therein. The pipe body is formed with an electrically conductive body. The contact piece is provided on the external circumferential surface of the pipe body and energizes the electrode through contact with the internal circumferential surface of the electrode. The contact piece has elasticity to produce a counterforce when pressed in the radial direction of the pipe body. The contact piece is formed with an electrically conductive body.

An electrode for a liquid-cooled plasma arc torch is provided that includes a torch body and a cathodic element. The electrode includes an electrode body having a proximal end and a distal end extending along a central longitudinal axis. The electrode also includes a retention region located at the proximal end of the electrode body. The retention region is shaped to engage a first portion of the torch body for retaining the electrode within the torch body. The electrode additionally includes a current interface region located axially proximal to the retention region on the electrode body. The current interface region configured to slidably engage a second portion of the torch body while electrically communicating with the cathodic element of the plasma arc torch. The electrode further includes a sealing member circumferentially disposed about the electrode body. The sealing member is located axially distal to the current interface region and the retention region.

The invention features methods and apparatuses for liquid cooling a plasma arc torch. An electrode is provided including a body having a longitudinal axis defining a first end, a second end, and a middle portion. The electrode includes a first sealing element disposed on an exterior of the body near the first end; a second sealing element disposed on the exterior of the body located in the middle portion, the second sealing element configured to provide a first gas seal to a swirl gas chamber and defining a portion of the swirl gas chamber; and a third sealing element disposed on the exterior of the body, the third sealing element located between the second sealing element and the second end, the third sealing element configured to provide a second gas seal to the swirl gas chamber and defining a portion of the swirl gas chamber.

Embodiments of the present invention are directed to an air cooled cutting torch having improved performance. The torch comprises an improved electrode, where the electrode has at least one gas flow port to allow air flow to pass through the electrode to improve cooling and performance.

A method of using a coolant tube in a liquid cooled plasma arc torch is provided. The method includes installing the coolant tube and a first electrode in the plasma arc torch. The method also includes biasing, by a first coolant flow, a biasing surface of the coolant tube against the first electrode, such that the coolant tube translates axially along the longitudinal axis to contact the first electrode. The biasing by the first coolant flow defines a first distance in an axial direction between the O-ring of the coolant tube and a proximal end of the first electrode. The method further includes removing the first electrode from the plasma arc torch and installing a second electrode in the torch. The method includes biasing, by a second coolant flow, the biasing surface of the coolant tube against the second electrode, such that the coolant tube translates axially along the longitudinal axis to contact the second electrode. The biasing by the second coolant flow defines a second distance in an axial direction between the O-ring of the coolant tube and a proximal end of the second electrode. A difference between the first distance and the second distance is at least about 0.25 inches.