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.

The invention features an inner cap for a liquid-cooled plasma arc torch. The inner cap includes a body having a longitudinal axis, a first end, and a second end. The first end includes an annular portion disposed proximate a torch tip. A liquid passage is formed within the body, is shaped to convey a liquid therethrough, and has a first set of ports formed in the annular portion. A gas passage is formed within the body, is shaped to convey a gas therethrough, and includes a second set of ports formed in the annular portion. The annular portion is configured such that subsets of ports in the first set of ports direct the liquid in a radial direction with respect to the longitudinal axis and alternate, in a rotational direction about the longitudinal axis, with subsets of ports in the second set of ports.

The invention features an inner cap for a liquid-cooled plasma arc torch. The inner cap includes a body having a longitudinal axis, a first end, and a second end. The first end includes an annular portion disposed proximate a torch tip. A liquid passage is formed within the body, is shaped to convey a liquid therethrough, and has a first set of ports formed in the annular portion. A gas passage is formed within the body, is shaped to convey a gas therethrough, and includes a second set of ports formed in the annular portion. The annular portion is configured such that subsets of ports in the first set of ports direct the liquid in a radial direction with respect to the longitudinal axis and alternate, in a rotational direction about the longitudinal axis, with subsets of ports in the second set of ports.

An electrode for a liquid-cooled plasma arc torch is provided that includes a torch body and a cathodic element. The electrode includes an electrode body having a proximal end and a distal end extending along a central longitudinal axis. The electrode also includes a retention region located at the proximal end of the electrode body. The retention region is shaped to engage a first portion of the torch body for retaining the electrode within the torch body. The electrode additionally includes a current interface region located axially proximal to the retention region on the electrode body. The current interface region configured to slidably engage a second portion of the torch body while electrically communicating with the cathodic element of the plasma arc torch. The electrode further includes a sealing member circumferentially disposed about the electrode body. The sealing member is located axially distal to the current interface region and the retention region.

The present disclosure related to a process and an apparatus for producing powder particles by atomization of a feed material in the form of an elongated member such as a wire, a rod or a filled tube. The feed material is introduced in a plasma torch. A forward portion of the feed material is moved from the plasma torch into an atomization nozzle of the plasma torch. A forward end of the feed material is surface melted by exposure to one or more plasma jets formed in the atomization nozzle. The one or more plasma jets being includes an annular plasma jet, a plurality of converging plasma jets. Powder particles obtained using the process and apparatus are also described.

The present disclosure related to a process and an apparatus for producing powder particles by atomization of a feed material in the form of an elongated member such as a wire, a rod or a filled tube. The feed material is introduced in a plasma torch. A forward portion of the feed material is moved from the plasma torch into an atomization nozzle of the plasma torch. A forward end of the feed material is surface melted by exposure to one or more plasma jets formed in the atomization nozzle. The one or more plasma jets being includes an annular plasma jet, a plurality of converging plasma jets. Powder particles obtained using the process and apparatus are also described.

A system, method and apparatus for recovering mining fluids from mining byproducts uses a plasma arc torch and a screw feed unit. The plasma arc torch includes a cylindrical vessel, a first tangential inlet/outlet connected to or proximate to a first end, a second tangential inlet/outlet connected to or proximate to a second end, an electrode housing connected to the first end 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 is connected to the second end such that the hollow electrode nozzle is aligned with the longitudinal axis, the hollow electrode nozzle is partially disposed within the cylindrical vessel and outside the cylindrical vessel. The screw feed unit has an inlet and an outlet, the outlet aligned with the centerline and proximate to the hollow electrode nozzle.

A system, method and apparatus for recovering mining fluids from mining byproducts uses a plasma arc torch and a screw feed unit. The plasma arc torch includes a cylindrical vessel, a first tangential inlet/outlet connected to or proximate to a first end, a second tangential inlet/outlet connected to or proximate to a second end, an electrode housing connected to the first end 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 is connected to the second end such that the hollow electrode nozzle is aligned with the longitudinal axis, the hollow electrode nozzle is partially disposed within the cylindrical vessel and outside the cylindrical vessel. The screw feed unit has an inlet and an outlet, the outlet aligned with the centerline and proximate to the hollow electrode nozzle.

A liquid coolant tube for a plasma arc cutting torch including a hollow elongated inner body shaped to translate within a hollow elongated outer body. The hollow elongated outer body of the liquid coolant tube is shaped to fixedly connect to the plasma arc cutting torch and includes a set of electrode guides. An external surface of the hollow elongated outer body and the set of electrode guides partially define a set of coolant flow channels between the set of electrode guides. The set of electrode guides are shaped to facilitate alignment of an electrode within the plasma arc cutting torch.

A liquid coolant tube for a plasma arc cutting torch including a hollow elongated inner body shaped to translate within a hollow elongated outer body. The hollow elongated outer body of the liquid coolant tube is shaped to fixedly connect to the plasma arc cutting torch and includes a set of electrode guides. An external surface of the hollow elongated outer body and the set of electrode guides partially define a set of coolant flow channels between the set of electrode guides. The set of electrode guides are shaped to facilitate alignment of an electrode within the plasma arc cutting torch.