Asymmetric consumables for a plasma arc torch

A torch tip assembly of a plasma arc torch for delivering a diffused stream of plasma arc to a workpiece to perform a gouging operation, the assembly comprising:

• a nozzle including (i) a nozzle body defining a central longitudinal axis extending between a proximal end and a distal end, (ii) a chamber in the nozzle body for receiving an electrode at the proximal end, and (iii) a nozzle exit orifice at the distal end of the nozzle body, the nozzle exit orifice defining at least a bore for conducting the plasma arc therethrough, the bore being disposed distally relative to the chamber, the bore having a first cross-sectional shape in a plane parallel to the longitudinal axis and a second cross-sectional shape in a plane perpendicular to the longitudinal axis;
• and
• a counter bore being fluidly connected to the chamber via the bore that is between the counter bore and the chamber, the counter bore located along the central longitudinal axis, the counter bore having a first cross-sectional shape in the plane parallel to the longitudinal axis and a second cross-sectional shape in the plane perpendicular to the longitudinal axis, the first cross-sectional shape of the counter bore being substantially rectangular;
• wherein at least one of the second cross-sectional shape of the bore or the second cross-sectional shape of the counter bore is non-circular, the at least one second non-circular cross-sectional shape of the bore or counter bore configured to facilitate a non-circular cross-sectional shape of the plasma arc adapted to diffuse the plasma arc in the workpiece;
• and
• wherein an area of the second cross-sectional shape of the counter bore at a proximal end of the counter bore is greater than an area of the second cross-sectional shape of the bore at a distal end of the bore.