Consumable assembly with internal heat removal elements

A method of cooling a consumable assembly, the method comprising:

• providing an electrode within an interior of a nozzle, the electrode having a proximal end and a distal end, and the electrode further comprising:
• a sidewall extending between the proximal end and the distal end of the electrode;
• one or more fluid passageways extending from an inner surface to an exterior surface of the sidewall;
• an end wall extending from the sidewall;
• a central cavity defined by an inner surface of the sidewall and an inner surface of the end wall, the central cavity extending from the proximal end to the distal end of the electrode;
• and
• a protrusion extending helically along the inner surface of the sidewall and radially into the central cavity, the protrusion and the inner surface of the sidewall defining a coolant passage;
• and
• directing a fluid into the central cavity of the electrode, through the coolant passage, and out the one or more fluid passageways, wherein the fluid is used as one or more of a plasma gas, a shield gas, and/or a vent gas.

An electrode for a plasma arc torch, the electrode comprising:

• a sidewall including one or more fluid passageways extending from an inner surface to an exterior surface of the sidewall;
• an end wall extending from a distal end of the sidewall, the end wall including an emissive insert formed therein;
• a central cavity defined by an inner surface of the sidewall and an inner surface of the end wall, the central cavity extending from a proximal end of the electrode to a distal end of the electrode;
• and
• a heat exchange element extending helically along the inner surface of the sidewall and radially into the central cavity from the inner surface of the sidewall, the heat exchange element and the inner surface of the sidewall forming a coolant passage.