A frame for a replaceable, unitary consumables cartridge configured for installation into a plasma arc torch. The frame includes a hollow body adapted to receive a translatable contact start electrode. The body has an internal surface and an external surface and includes: a substantially cylindrical metallic core; an electrically insulative overmolded plastic casing at least substantially surrounding a circumference of a distal end of the substantially cylindrical metallic core; and a set of flow passages fluidly connecting the external surface of the hollow body and the internal surface of the hollow body, the flow passages offset to impart a swirling fluid flow pattern to a plasma gases passing therethrough.

A cartridge for an air-cooled plasma arc torch is provided. The cartridge includes a swirl ring having a molded thermoplastic elongated body with a distal end, a proximal end, and a hollow portion configured to receive an electrode. The swirl ring also has a plurality of gas flow openings defined by the distal end of the elongated body and configured to impart a swirling motion to a plasma gas flow for the plasma arc torch. The swirl ring further includes a nozzle retention feature on a surface of the elongated body at the distal end for retaining a nozzle to the elongated body. The cartridge further includes a cap affixed to the proximal end of the elongated body of the swirl ring for substantially closing the proximal end of the elongated body.

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.

In the case of the nozzle protection cap (7) according to the invention for a plasma arc torch (1), is arranged and fastened at the outside on the tip of the plasma arc torch (1), at which a plasma jet emerges from the plasma arc torch (1) through nozzle-like openings (4a, 7a). The nozzle protection cap (7) is produced from an iron alloy including sulfur in a fraction of at least 0.05%.

A device for generating an atmospheric plasma beam for treating the surface of a workpiece includes a tubular housing with an axis, an inner electrode within the housing, and a nozzle assembly with a nozzle opening for discharging a plasma beam to be generated in the housing. The direction of the nozzle opening runs at an angle relative to the axis, and the nozzle assembly can be rotated about the axis. By the aforementioned device, disadvantages are at least partly eliminated and uniform treatment of the surface is achieved in that a shield surrounds the nozzle assembly, and the shield is designed to change the intensity of the interaction of the plasma beam to be generated with the surface of the workpiece depending on the rotational angle of the nozzle assembly relative to the axis. Also provided are a system and method for treating the surface of a workpiece.

A consumable cartridge for a liquid-cooled plasma arc torch is provided. The consumable cartridge comprises a cartridge frame including a proximal end having an end surface, a distal end and a body having a central longitudinal axis extending therethrough. The cartridge configured to form a radio-frequency identification (RFID) interface with a torch head. The consumable cartridge also comprises an arc emitter and an arc constrictor affixed to the cartridge frame at the distal end and an RFID mounting feature formed on or in the cartridge frame adjacent to the end face. The RFID mounting feature is non-concentric with the central longitudinal axis of the body. The consumable cartridge further comprises an RFID tag disposed in or on the RFID mounting feature for transmitting information about the cartridge to a reader device in the torch head when the cartridge is connected to the torch head.

The invention features a frame for a plasma arc torch cartridge. The frame includes a thermally conductive frame body having a longitudinal axis, a first end configured to connect to a first consumable component, and a second end configured to mate with a second consumable component. The frame body surrounds at least a portion of the second consumable component. The frame also includes a set of flow passages formed within the frame body. The set of flow passages fluidly connects an internal surface of the frame body and an external surface of the frame body. The set of flow holes is configured to impart a fluid flow pattern about the second consumable component.

The invention relates to a single or multipart insulating component for a plasma torch, particularly a plasma cutting torch, for electrical insulation between at least two electrically conductive components of the plasma torch, characterized in that the insulating component consists of an electrically non-conductive and easily thermally conductive material, or at least one part thereof consists of an electrically non-conductive and easily thermally conductive material. The invention further relates to assemblies and plasma torches having the same and to a method for processing, plasma cutting and plasma welding.

A plasma arc torch includes a nozzle body, a nozzle extending from the nozzle body, and a shield cap. An outer retaining cap is attached to the plasma arc torch and secures the shield cap to the plasma arc torch. A sleeve is located radially outward from the outer retaining cap and is configured to receive a flow of pressurized gas. An insulator is located between the outer retaining cap and the sleeve. At least one of the sleeve and the insulator forms a gas flow channel configured to direct a gas flow from the sleeve to a distal portion of the outer retaining cap.

Thermal spray gun (1) and/or nozzle (120) includes a nozzle body and a liner material (123) arranged within the nozzle body. A material of the nozzle body has a lower melting temperature than that of the liner material (123). A wall thickness (C) of the liner material (123) has a value determined in relation to or that corresponds to a wall thickness (D) of the nozzle body. Alternatively or additionally, a ratio of a total wall thickness of a portion of a nozzle (120) to that of a wall thickness (C) of the liner material (123) has a value determined in relation to or that corresponds to the wall thickness (C) of liner material (123).