A high velocity plasma spray method and apparatus with relatively high plasma pressures of 3 bars or above. The preferable range of plasma pressure is 3 bars to 10 bars and a plasma enthalpy of preferably 10 KJ/g or above. The preferable enthalpy range is above 10 KJ/g and up to 20 KJ/g and the preferred specific power (?) is in the range of 16 KJ/g to 33 KJ/g.

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.

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.

Disclosed is a demountable tube for a plasma torch assembly, such as an ICP torch assembly. The tube includes an open tubular body for radially surrounding a plasma within the tubular body. The tubular body may comprise a wall; and a mounting feature projecting from the tubular body for at least one of: (i) controlling alignment of the tubular body with respect to a mounting portion of the torch assembly, and (ii) releasably securing the tubular body to a portion of the torch assembly. The tubular body may also have a transmission zone that is partially devoid of said wall and includes at least one hole through said wall. The tube may be opaque. A plasma torch and ICP spectroscopy system are also disclosed.

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.

The disclosure provides an air disinfection and filtration apparatus for the removal of particles and disinfection of a flow of air using plasma. The apparatus comprises an electrode section with coaxial electrodes that form an annular cavity between the coaxial electrodes. Further, the apparatus comprises an ionic thruster assembly connected to the annular cavity of the electrode section. The ionic thruster assembly includes a top inlet and is configured to receive an airflow, charge the particles within the airflow, and transmit the airflow with the charged particles into the annular cavity of the electrode section. Further, the electrode section is configured to attract the charged particles towards an outer electrode of the coaxial electrodes. The apparatus further comprises a swirl generation unit, a catalytic bed, a particle collector, a collector adaptor, and a dome-shaped closure member.

A plasma jet generator includes a base, a jet gun cavity, a blocking insulating medium, a porous air intake plate, a high-voltage port, a high-voltage electrode housing, and a jet gun tip. The base is detachably connected to a first end of the jet gun cavity. The blocking insulating medium is inserted in the base. The porous air intake plate is detachably mounted in the blocking insulating medium. The high-voltage electrode housing is detachably mounted in the porous air intake plate. The high-voltage port is disposed in the high-voltage electrode housing. The jet gun tip is detachably mounted at a second end of the jet gun cavity.

A plasma cutting system is provided. The system includes a power source configured to generate a plasma arc, and a plasma arc torch connected to the power source for delivering the plasma arc to a workpiece. The plasma arc torch defines a multi-function fluid flow path for sustaining the plasma arc and cooling the plasma arc torch such that the plasma cutting system has a power-to-gas flow ratio of at least 2 kilowatts per cubic feet per minute (KW/cfm). The power-to-gas flow ratio comprises a ratio of power of the generated plasma arc to a total gas flow supplied to the plasma arc torch.

An electrode-supporting assembly for a contact-start plasma arc torch has an insulator that partially houses an electrode, and employs a spring-loaded plunger to bias the electrode to a forward position. The spring is engaged between the plunger and a contact element attached to the insulator, and may conduct electrical current to the electrode. The plunger, spring, and contact element are retained in the insulator when the torch is opened to replace the electrode, which is a consumable part. The electrode and the plunger have axially-engagable mating surfaces to assure good thermal and electrical conductivity therebetween. Conductivity can be further enhanced by forming the plunger of silver or a silver-bearing alloy. In some embodiments, a passage through the insulator is partitioned into forward and rear chambers, with the plunger, spring, and contact element trapped in the rear chamber.

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.