Cartridge for a liquid-cooled plasma arc torch

A consumable cartridge of a liquid-cooled plasma arc torch, the consumable cartridge comprising:

• an electrode having a substantially hollow body and a plurality of flanges disposed circumferentially about an external surface of the hollow body;
• an insulator circumferentially disposed about a portion of the external surface of the hollow body of the electrode, the plurality of flanges of the electrode in cooperation with the insulator to define a gas chamber between the electrode and the insulator;
• a nozzle circumferentially disposed about the electrode and physically connected to the electrode via the insulator, wherein the nozzle comprises a nozzle jacket and a nozzle body, the nozzle jacket circumferentially disposed about an external surface of the nozzle body and defining a chamber therebetween;
• and
• a cartridge frame comprising an electrically insulating material with at least one cooling channel extending therethrough, wherein a proximal portion of the nozzle is disposed within and coupled to the cartridge frame.

A method for conducting one or more fluid flows through a consumable cartridge of a plasma arc torch, the method comprising:

• providing a consumable cartridge comprising a cartridge frame coupled to a nozzle that is couples to an electrode via an insulator, the electrode comprising at least a proximal flange and a distal flange disposed circumferentially about an external surface of a hollow body of the electrode;
• providing a plasma gas flow to the external surface of the hollow body of the electrode;
• conducting the plasma gas flow through at least one hole on the proximal flange of the electrode to a chamber created between the proximal and distal flanges of the electrode, the chamber being bounded axially by the proximal and distal flanges and radially by the external surface of the hollow body of the electrode and the insulator;
• metering and swirling the plasma gas flow as the plasma gas flow exits the chamber via at least one hole on the distal flange;
• and
• conducting the plasma gas flow distally to a plasma chamber defined between a distal end of the electrode and the nozzle.