Welding diffuser insert

A diffuser assembly for a welding torch;

• said diffuser assembly comprising:
• a diffuser body having a first end and a second end positioned opposite said first end, said diffuser body having a longitudinal axis extending from said first end to said second end;
• an interior chamber positioned between said first end and said second end, where said interior chamber is open at said first end to permit a flow of a gas into said interior chamber from said first end, where said interior chamber is open at said second end to permit insert of a contact tip, and where said diffuser body has a wall portion between said first and second ends;
• a plurality of openings in said wall portion which are symmetrically distributed, where said plurality of openings pass through said wall portion to permit said flow of said gas to exit said diffuser body through said plurality of openings;
• and
• a diffuser insert positioned within said interior chamber, where said diffuser insert seats within said interior chamber and where said diffuser insert is exposed to an outside of said diffuser body through said plurality of openings, where said diffuser insert along a longitudinal position of said diffuser insert overlaps with said openings along an entire longitudinal length of said openings, when viewed from a radial direction with respect to said diffuser body;
• wherein said diffuser insert has an upstream cavity portion and a downstream bore portion, each of which are co-axial with said longitudinal axis, where said upstream cavity portion has a larger diameter than said downstream bore portion and said diffuser insert is oriented such that said upstream cavity portion is open to said first end of said diffuser body, and where said downstream bore portion extends from said upstream cavity portion to a downstream end face of said diffuser insert;
• wherein said diffuser insert has a plurality of flow features on a sidewall of said diffuser insert which manipulate said flow of said gas to direct said flow of said gas from said interior chamber to said plurality of said openings, and
• wherein said diffuser insert is removable and secured in a press-fit relationship with said diffuser body.

A diffuser assembly for a welding torch;

• said diffuser assembly comprising:
• a diffuser body having a first end and a second end positioned opposite said first end, said diffuser body having a longitudinal axis extending from said first end to said second end;
• an interior chamber positioned between said first end and said second end, where said interior chamber is open at said first end to permit a flow of a gas into said interior chamber from said first end, where said interior chamber is open at said second end to permit insert of a contact tip, and where said diffuser body has a wall portion between said first and second ends;
• a plurality of openings in said wall portion which are symmetrically distributed, where said plurality of openings pass through said wall portion to permit said flow of said gas to exit said diffuser body through said plurality of openings;
• and
• a diffuser insert positioned within said interior chamber, where said diffuser insert seats within said interior chamber and where said diffuser insert is exposed to an outside of said diffuser body through said plurality of openings, where said diffuser insert along a longitudinal position of said diffuser insert overlaps with said openings along an entire longitudinal length of said openings, when viewed from a radial direction with respect to said diffuser body;
• wherein said diffuser insert has an upstream cavity portion and a downstream bore portion, each of which are co-axial with said longitudinal axis, where said upstream cavity portion has a larger diameter than said downstream bore portion and said diffuser insert is oriented such that said upstream cavity portion is open to said first end of said diffuser body, and where said downstream bore portion extends from said upstream cavity portion to a downstream end face of said diffuser insert;
• wherein an outer surface of said diffuser insert has an axially extending feature to provide said flow of said gas to said plurality of said openings, and
• wherein said diffuser insert is secured in a press-fit relationship with said diffuser body.

A diffuser assembly for a welding torch;

• said diffuser assembly comprising:
• a diffuser body having a first end and a second end positioned opposite said first end, said diffuser body having a longitudinal axis extending from said first end to said second end;
• an interior chamber positioned between said first end and said second end, where said interior chamber is open at said first end to permit a flow of a gas into said interior chamber from said first end and where said interior chamber is defined by a wall portion of said diffuser body;
• a plurality of openings in said wall portion of said interior chamber where said plurality of openings pass through said wall portion to permit said flow of said gas to exit said interior chamber through said plurality of openings;
• and
• a diffuser insert positioned entirely within said interior chamber, where said diffuser insert seats within said interior chamber and where said diffuser insert is exposed to an outside of said diffuser body through said plurality of openings;
• wherein said diffuser insert has an upstream cavity portion and a downstream bore portion, each of which are co-axial with said longitudinal axis, where said upstream cavity portion has a larger diameter than said downstream bore portion and said diffuser insert is oriented such that said upstream cavity portion is open to said first end of said diffuser body, and where said downstream bore portion extends from said upstream cavity portion to a downstream end face of said diffuser insert;
• wherein said diffuser insert has at least one flow feature on a sidewall of said diffuser insert that is at least one of a depression, groove and slot to manipulate said flow of said gas to direct said flow of said gas from said interior chamber to said plurality of said openings;
• and
• wherein at least a portion of said diffuser insert along a longitudinal position of said diffuser insert overlaps with said openings along an entire longitudinal length of said openings, when viewed from a radial direction with respect to said diffuser body.