In some aspects, electrodes can include a front portion shaped to matingly engage a nozzle of the plasma cutting system, the front portion having a first end comprising a plasma arc emitter disposed therein; and a rear portion thermally connected to a second end of the front portion, the rear portion shaped to slidingly engage with a complementary swirl ring of the plasma cutting system and including: an annular mating feature extending radially from a proximal end of the rear portion of the electrode to define a first annular width to interface with the swirl ring, the annular mating feature comprising a sealing member configured to form a dynamic seal with the swirl ring to inhibit a flow of a gas from a forward side of the annular mating feature to a rearward side of the annular mating feature.

A torch tip is provided for a liquid-cooled plasma arc cutting torch. The torch tip includes an electrode with an elongated electrode body having a distal end and a proximal end extending along a longitudinal axis. The electrode body includes at least one interior threaded connection at the proximal end for engaging a liquid-cooled electrode holder. The electrode holder comprises a liquid coolant channel that does not extend into the electrode body. The electrode body has (i) a length extending along the longitudinal axis and (ii) a diameter associated with a widest portion of the electrode body along the longitudinal axis between the proximal and distal ends, where a ratio of the length to the diameter of the electrode body is greater than about 5.

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 plasma torch has a multi-electrode front electrode and a button-type rear electrode. The plasma torch allows initial discharge to be easily performed by using the button-type rear electrode and an auxiliary electrode for discharge. Initial ignition of a high-output arc plasma torch is performed easily by naturally forming an arc column between the rear electrode and the front electrode, even in the absence of efficient discharge between the rear electrode and the auxiliary electrode for initial discharge.

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.

A discharge electrode E in an electrode chamber C comprises a plurality of electrode members 8, 9. The electrode members 8, 9 are disposed facing each other by having a supporting member 4 therebetween, a gap is formed between the facing portions of the electrode members 8, 9, and by having the gap as a gas passageway 15, the gas passageway is opened in the leading end of the discharge electrode. A replacement gas having been supplied from a manifold pipe 3 is supplied to the gas passageway 15 via an orifice.

A nozzle for a plasma arc torch has a longitudinal nozzle axis, a nozzle orifice with a generally cylindrical orifice sidewall centered on the nozzle axis, and an orifice inlet that is formed as a surface of rotation about the nozzle axis; a gas-directing surface may also be provided. The orifice inlet has a variably-curved surface generated by rotating a variably-curved element about the nozzle axis, where the variably-curved element can be a portion of an ellipse, parabola, or hyperbola, and can join to the orifice sidewall and to the gas-directing surface, if provided. Both the orifice sidewall and the gas directing surface can each join the variably-curved element in a substantially tangential manner. Using an elliptical contour for the orifice inlet was found to increase stability for the plasma arc, providing improved cut quality and faster cutting speed for the torch.

A silver-copper cutting electrode assembly, and method of manufacture is provided with optimized attributes to allow for improved durability, integrity and manufacturability. An electrode has a silver tip portion which is brazed to a copper body portion where the silver portion and joint have a particular structural relationship.

A silver-copper cutting electrode assembly, and method of manufacture is provided with optimized attributes to allow for improved durability, integrity and manufacturability. An electrode has a silver tip portion which is brazed to a copper body portion where the silver portion and joint have a particular structural relationship.

A silver-copper cutting electrode assembly, and method of manufacture is provided with optimized attributes to allow for improved durability, integrity and manufacturability. An electrode has a silver tip portion which is brazed to a copper body portion where the silver portion and joint have a particular structural relationship.