Nozzles for plasma torches and plasma torch systems utilizing such nozzles are provided herein. One such nozzle may include a body having a first end, a second end having an exit orifice disposed therein, and a passageway extending from the first end to the second end and adapted to enable the flow of plasma gas from the first end, through the passageway, and to the exit orifice. Greater than or equal to approximately 50% of an overall mass of the body is distributed between the second end and a midpoint of the body with respect to a longitudinal length of the body.

A plasma generator capable of detecting whether a connector of a head is electrically connected to a power cable. When the connector of the plasma head is electrically connected to the cable harness, a signal current flows in a path from the controller to the ground via a photocoupler, a relay, a cable, a terminal, another terminal, and a first ground cable in response to a pulse signal outputted from the controller. Accordingly, the plasma generator is able to detect whether the connector of the head is electrically connected to the first power cable and the second power cable, based on whether the photocoupler detects a signal current.

A method of making and assembling together components of a plasma torch electrode inside an oxygen-free environment. According to one implementation the method includes machining an outer surface of an emitter to produce an oxide free outer surface and machining an opening in a distal end of a main body of the electrode, the opening being bound by an oxide-free inner surface of the main body after the machining. In the oxygen-free environment, the emitter is then secured inside the opening of the main body such that the oxide-free outer surface of the emitter is secured to the oxide-free inner surface of the main body.

A replacement part unit for a plasma torch includes an electrode, an insulation guide, and a nozzle. The insulation guide includes a hole into which the electrode is inserted. The insulation guide is coupled to the electrode by press-fitting or adhesion. The nozzle includes a hole into which the insulation guide is inserted. The nozzle is coupled to the insulation guide by press-fitting or adhesion.

A plasma spraying device includes a torch head which has a plasma channel that extends between a cathode and an anode. The plasma channel is bounded by a plurality of neutrodes which are electrically insulated from each other. A gap extends between the frontmost neutrode and the anode, which gap is divided into at least two sections. There is a radial distance and an axial distance between the two sections. An insulating disk is arranged in each of the two sections.

Embodiments of arc plasma cutting torches are disclosed. In one embodiment, a plasma cutting torch includes an insert component located substantially between a cathode body and an insulator body. The insert component is able to withstand high temperatures and can be made of a metal material or a non-metal material. The insert component can be permanent within the torch or can be replaceable, in accordance with various embodiments.

Nozzle for a plasma torch head, laser cutting head or plasma laser cutting head, arrangement composed of such a nozzle and of a nozzle protection cap, arrangement composed of such a nozzle and of an electrode, plasma torch head, laser cutting head or plasma laser cutting head having such a nozzle and/or having such an arrangement, plasma torch comprising such a plasma torch head, laser cutting head comprising such a nozzle and/or such an arrangement, plasma laser cutting head comprising such a nozzle and/or such an arrangement, method for plasma cutting, method for laser cutting and method for plasma laser cutting using the same.

A nozzle for a liquid cooled plasma arc cutting torch is provided. The nozzle includes a hollow nozzle body and a nozzle jacket disposed about an external surface of the nozzle body. The jacket defines (i) a length along the central longitudinal axis and (ii) a diameter of a distal tip of the jacket at the distal region of the nozzle, where the length is greater than about 1.5 inches and a ratio of the length to the diameter is greater than about 1.4. The nozzle also includes a coolant inlet and a coolant outlet defined between the nozzle body and nozzle jacket at the proximal region of the nozzle. The nozzle further includes a plurality of coolant channels cooperatively defined between the nozzle body and the nozzle jacket. The plurality of coolant channels extend axially between the proximal region and the distal region of the nozzle.

A plasma nozzle (120) having a nozzle body and a liner material (123) arranged within the nozzle body. The liner material (123) has a higher melting temperature than the nozzle body and includes one of a Tungsten alloy having a cross-sectional thickness (C) significantly greater than 0.25 mm, Molybdenum, Silver and Iridium.

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.