The invention features a replaceable cartridge for a plasma arc torch. The cartridge includes a cartridge body having a first section and a second section. The first and second sections are joined at an interface to form a substantially hollow chamber. The interface provides a coupling force that secures the first and second sections together. The cartridge also includes an arc constricting member located in the second section; an electrode included within the substantially hollow chamber; and a contact start spring element affixed to the electrode. The spring element imparts a separating force that biases the electrode toward at least one of the first section or the second section of the body. The separating force has a magnitude that is less than a magnitude of the coupling force.

Embodiments of the present invention include a plasma cutting system having a plasma cutting power supply. The plasma cutting power supply outputs a pierce current which is higher than a maximum operational current rating for a torch for the cutting operation for a determined duration. After the expiration of the duration the output current is reduced to a cutting current level. Embodiments allow for the cutting of thicker materials than known systems.

The present invention relates to a plasma torch including: a tube including: a first diameter part provided with a hollow channel; and a second diameter part provided at a predetermined position on the outer circumferential surface of the first diameter part; a body including: a housing part receiving the tube therein; and a plurality of first and second discharge holes formed at predetermined positions in longitudinal directions of the body; an insulator including a plurality of first discharge flow lines formed at predetermined positions vertically located from the body; an amplification tube including a space part communicating with the second discharge holes; a housing including a plurality of second discharge flow lines formed at predetermined positions of an inner circumferential surface of the housing; an inner cap combined with an outer circumferential surface of the housing; and an insulation cap engaged with an outer circumferential surface of the inner cap.

A replaceable cartridge for a plasma arc torch includes a cartridge body having a first section and a second section. The first and second sections are joined at an interface to form a substantially hollow chamber. The interface provides a coupling force that secures the first and second sections together. The cartridge also includes an arc constricting member located in the second section; an electrode included within the substantially hollow chamber; and a contact start spring element affixed to the electrode. The spring element imparts a separating force that biases the electrode toward at least one of the first section or the second section of the body. The separating force has a magnitude that is less than a magnitude of the coupling force.

In some aspects, nozzles for a plasma arc torch can include a first body having a first end, a second end, and a longitudinal axis; and a second body disposed about a portion of the first body to complement the first body, the second body defining a set of channels formed on an internal surface shaped to form a set of liquid flow passages between the first body and the second body, the second body at least partially defining at least one inlet and at least one outlet to the set of liquid flow passages.

Nozzle for a plasma torch, said nozzle comprising: an internal component (37, 137) which defines an internal pass-through cavity to form a plasma chamber having an outlet opening (7, 107), an external component (38, 138) which at least partially and coaxially surrounds the internal component (37, 137) and which has a distal conical region, a proximal cylindrical region and an intermediary region (8, 108) between those, wherein radial protrusions (29, 129) are arranged with a mutual angular spacing at an external surface of the external component (38, 138) along a common radial plane between the intermediary region (8, 108) and the proximal cylindrical region.

A nozzle for a gas-cooled plasma arc torch is provided. The nozzle includes a nozzle body formed from a first metal. The nozzle body comprises a proximal portion and a distal portion extending along a longitudinal axis. The distal portion of the nozzle body comprises a first bore. The nozzle also includes an arc transition component formed from a second metal. The arc transition component is coupled to the distal portion of the nozzle body and comprises a second bore configured to substantially align with the first bore when the arc transition component is coupled to the nozzle body. The second metal of the arc transition component comprises a noble metal and the second metal is different from the first metal.

The invention features methods and apparatuses for regulating a shielding liquid in a plasma torch. A liquid-injection shield for a plasma torch includes a body having an exterior surface and an interior surface and a liquid injection regulation component circumferentially disposed within and in direct contact with the interior surface of the body. The liquid injection regulation component and the interior surface of the body define a chamber. The liquid injection regulation component also defines a first set of ports sized to regulate a liquid entering the chamber and a second set of ports oriented to distribute a fluid exiting the chamber.

A plasma spraying apparatus includes a cathode, a first gas nozzle surrounding a head of the cathode therewith to form a first gas path outside of the cathode, and a second gas nozzle surrounding the first gas nozzle therewith to form a second gas path outside of the first gas nozzle. The second gas nozzle is formed with a wire path through which a wire is inserted such that a distal end of the wire is disposed in front of a nozzle opening of the second gas nozzle. The wire path has a substantially rectangular cross section having a longer side extending in a direction in which a plasma flame extends, the wire path causing the wire to bend within an elastic limit of the wire.

A plasma torch assembly, and components thereof, is provided with optimized attributes to allow for improved torch durability add versatility. A torch nozzle is provided having a novel design, including exterior cooling channels running along a length of the nozzle. An improved inner retaining cap assembly is provided which imparts a swirl on shield gas flow. Additionally, a shield cap and outer retainer have optimized geometries to allow the torch to be made narrower to facilitate the cutting of complex 3-D shapes and bevel cuts not attainable with known mechanized plasma torches.