A consumable exchanger for a plasma arc material processing system is provided. The consumable exchanger comprises a base portion and a holder shaped to retain at least a portion of a consumable component of a plasma arc torch. The holder is operably connected to the base portion. The consumable exchanger further comprises a driver connected to the holder. The driver is configured to rotate the consumable component relative to at least one of the base portion or the plasma arc torch to perform one of engage the consumable component to the plasma arc torch or disengage the consumable component from the plasma arc torch.

A plasma gas swirl ring for a liquid cooled plasma arc torch is provided. The swirl ring comprises a substantially hollow body having a distal end, a proximal end, an interior region defined by an interior surface, and an exterior surface. The interior region of the body is configured to receive an electrode of the plasma arc torch. The swirl ring comprises a first opening disposed within a portion of the proximal end of the body, a second opening disposed about a central portion of the body, and a third opening comprising at least one swirling port disposed within a portion of the distal end of the body. The third opening is configured to provide a swirling flow of the plasma gas about the electrode at the distal end of the body.

A plasma gas swirl ring for a liquid cooled plasma arc torch is provided. The swirl ring comprises a substantially hollow body having a distal end, a proximal end, an interior region defined by an interior surface, and an exterior surface. The interior region of the body is configured to receive an electrode of the plasma arc torch. The swirl ring comprises a first opening disposed within a portion of the proximal end of the body, a second opening disposed about a central portion of the body, and a third opening comprising at least one swirling port disposed within a portion of the distal end of the body. The third opening is configured to provide a swirling flow of the plasma gas about the electrode at the distal end of the body.

A plasma treatment system includes a plasma arc torch, a tee attached to a hollow electrode nozzle of the plasma arc torch, and a screw feed unit or a ram feed unit having an inlet and an outlet attached to the tee. The plasma arc torch includes a cylindrical vessel having a first end and a second end, a first tangential inlet/outlet connected to or proximate to the first end, a second tangential inlet/outlet connected to or proximate to the second end, an electrode housing connected to the first end of the cylindrical vessel such that a first electrode is (a) aligned with a longitudinal axis of the cylindrical vessel, and (b) extends into the cylindrical vessel, and a hollow electrode nozzle connected to the second end of the cylindrical vessel such that a centerline of the hollow electrode nozzle is aligned with the longitudinal axis of the cylindrical vessel.

A plasma treatment system includes a plasma arc torch, a tee attached to a hollow electrode nozzle of the plasma arc torch, and a screw feed unit or a ram feed unit having an inlet and an outlet attached to the tee. The plasma arc torch includes a cylindrical vessel having a first end and a second end, a first tangential inlet/outlet connected to or proximate to the first end, a second tangential inlet/outlet connected to or proximate to the second end, an electrode housing connected to the first end of the cylindrical vessel such that a first electrode is (a) aligned with a longitudinal axis of the cylindrical vessel, and (b) extends into the cylindrical vessel, and a hollow electrode nozzle connected to the second end of the cylindrical vessel such that a centerline of the hollow electrode nozzle is aligned with the longitudinal axis of the cylindrical vessel.

A thermal metal spraying apparatus for applying a metal coating to a target surface. The apparatus provides a cathode, a wire feed stock having a free end, and a wire guide that directs the free end of the wire feedstock to a position for establishing and maintaining a plasma transferred wire arc between the cathode and the free end of the wire feedstock. The wire guide maintains at least three points of contact with the wire feedstock as the wire feedstock is fed through the wire guide.

A thermal metal spraying apparatus for applying a metal coating to a target surface. The apparatus provides a cathode, a wire feed stock having a free end, and a wire guide that directs the free end of the wire feedstock to a position for establishing and maintaining a plasma transferred wire arc between the cathode and the free end of the wire feedstock. The wire guide maintains at least three points of contact with the wire feedstock as the wire feedstock is fed through the wire guide.

A plasma torch excitation device includes an electrode core frame having a chamber; an electrode implanted in the chamber to form a gas collecting conduit surrounding between the electrode and a wall of the chamber; and an electrode housing fixed at a bottom end of the electrode core frame, the electrode housing having a core bore, the inner end of the core bore communicating with the gas collecting conduit, the outer end serving as a blasting port of the plasma torch. The electrode has an electric ion projecting end, the electric ion projecting end is adjacent to the inner end of the core bore, and a conical bore wall is formed between the inner end and the outer end of the core bore, the conical bore wall is formed by the inner end gradually expanding to the outer end. It can solve the conventional problems of well-known plasma torches, such as, limitation of flame temperature and flame length due to shortness of the core bore.

A plasma torch excitation device includes an electrode core frame having a chamber; an electrode implanted in the chamber to form a gas collecting conduit surrounding between the electrode and a wall of the chamber; and an electrode housing fixed at a bottom end of the electrode core frame, the electrode housing having a core bore, the inner end of the core bore communicating with the gas collecting conduit, the outer end serving as a blasting port of the plasma torch. The electrode has an electric ion projecting end, the electric ion projecting end is adjacent to the inner end of the core bore, and a conical bore wall is formed between the inner end and the outer end of the core bore, the conical bore wall is formed by the inner end gradually expanding to the outer end. It can solve the conventional problems of well-known plasma torches, such as, limitation of flame temperature and flame length due to shortness of the core bore.

An electrode for a plasma arc torch includes a generally cylindrical elongated body formed of an electrically conductive material. The elongated body includes a proximal end that connects to a power supply and a distal end that receives an emissive element. The electrode can include a flange that is disposed about a surface relative to the distal end of the elongated body, extends radially from the surface of the elongated body, and is utilized to establish a uniform gas flow distribution of a plasma gas flow about the distal end of the elongated body. The electrode can include a contact element that is in electrical communication with the proximal end of the electrode. The contact element includes seating portion that has an outer width that is greater than the outermost diameter of the electrode body and is configured to position the contact element within the plasma arc torch.