Forward Flow, High Access Consumables for a Plasma Arc Cutting Torch

A method of cutting a workpiece comprising:

• providing a plasma arc torch having a body which includes a flow path for directing a plasma gas through a swirl ring to a plasma chamber in which a plasma arc is formed;
• providing a nozzle mounted relative to an electrode at a distal end of the torch body to define the plasma chamber, the nozzle comprising:
• a substantially hollow, elongated body capable of receiving the electrode, the nozzle body defining a longitudinal axis and having a length along the axis from a first end of the nozzle body to a second end of the nozzle body;
• a plasma exit orifice disposed at the first end of the nozzle body, wherein the first end of the nozzle body has a width and a ratio of the length of the nozzle body to the width of the nozzle body is greater than about 3;
• and
• at least one supplemental orifice disposed through at least one of an end face or a side wall of the nozzle, the at least one supplemental orifice relative to the plasma exit orifice;
• operating the plasma arc cutting torch at an amperage level of at least about 15 Amps;
• and
• flowing substantially all of a cooling gas through the at least one supplemental orifice at the distal end of the torch body.

A nozzle assembly for a plasma arc cutting torch, the nozzle assembly comprising:

• a substantially hollow, elongated body defining a longitudinal axis and having a length along the axis from a first end of the body to a second end of the body;
• a plasma exit orifice disposed at the first end of the body;
• and
• a structure configured to translatably receive an electrode and integrally formed with the nozzle body, the structure comprising a body with canted gas ports to provide a swirling plasma gas during operation of the plasma arc cutting torch.

A method of cutting a workpiece comprising:

• providing a nozzle assembly mounted relative to an electrode at a distal end of a torch body to define a plasma chamber, the nozzle assembly comprising:
• a substantially hollow, elongated body defining a longitudinal axis and having a length along the axis from a first end of the body to a second end of the body;
• a plasma exit orifice disposed at the first end of the nozzle body;
• at least one supplemental orifice disposed through an end face of the nozzle assembly relative to the plasma exit orifice;
• and
• a structure configured to translatably receive an electrode and integrally formed with the nozzle body, the structure comprising a body with canted gas ports to provide a swirling plasma gas during operation of the plasma arc cutting torch;
• operating the plasma arc cutting torch at an amperage level of at least about 15 Amps;
• and
• flowing substantially all of a cooling gas through the at least one supplemental orifice.

An electrode for a high visibility plasma arc cutting torch comprising:

• an elongated electrode body having a first end and a second end, the body defining a bore in the first end for receiving an insert, the electrode body including:
• (i) a first body portion extending from the first end;
• (ii) a second body portion extending to the second end;
• and
• (iii) a heat transfer zone located relative to the first body portion at the first end of the electrode body,
• wherein during operation of the plasma torch at a current greater than about 15 Amps, the heat transfer zone is in thermal communication with a cooling gas and is configured such that a majority heat generated during the operation of the plasma torch is removed from the heat transfer zone.

An electrode for a high visibility plasma arc cutting torch comprising:

• an elongated electrode body having a first end and a second end, the body defining a bore in the first end for receiving an insert, the electrode body including:
• (i) a first body portion extending from the first end;
• (ii) a second body portion extending to the second end;
• and
• (iii) a heat transfer zone located relative to the first body portion at the first end of the electrode body,
• wherein the heat transfer zone is greater than about 1 square inch.

A torch tip for a handheld plasma torch, the handheld plasma torch having a trigger and a torch tip mount, the torch tip comprising:

• a substantially hollow nozzle;
• an electrode disposed relative to the nozzle;
• and
• a housing disposed relative to the nozzle and the electrode, the nozzle, electrode and housing forming an assembled torch tip having a distal end and a proximal end, the proximal end of the assembled torch tip configured to couple to the torch tip mount,
• wherein a distance from the distal end to the proximal end of the assembled torch tip is greater than about 3 inches.

A torch tip for a handheld plasma torch, the handheld plasma torch having a trigger and a torch tip mount, the torch tip comprising:

• a substantially hollow nozzle;
• an electrode disposed relative to the nozzle;
• and
• a housing disposed relative to the nozzle and the electrode, the nozzle, electrode and housing forming an assembled torch tip having a distal end and a proximal end, the proximal end of the assembled torch tip configured to couple to the torch tip mount, the assembled torch tip defining a longitudinal axis and having a length along the axis from the proximal end to the distal end,
• wherein a ratio of the length of the assembled torch tip to a width of the assembled torch tip is greater than about 3.

A method of aligning an electrode in a plasma arc torch, the method comprising:

• providing a nozzle assembly comprising:
• a substantially hollow, elongated body capable of receiving an electrode, the body defining a longitudinal axis and having a length along the axis from a first end of the body to a second end of the body;
• a plasma exit orifice disposed at the first end of the body;
• and
• a structure integrally formed with the nozzle body, the structure comprising a body with canted gas ports to provide a swirling plasma gas during operation of the plasma arc cutting torch,
• disposing an elongated electrode within the body of the nozzle, the electrode having a first end and a second end, the electrode body defining a bore in the first end of the electrode for receiving an insert;
• and
• aligning the bore of the electrode with the plasma exit orifice of the nozzle via the structure.

A method for extending the life of a plasma arc torch, the method comprising:

• providing a torch body which includes a plasma gas flow path for directing a plasma gas through a swirl ring to a plasma chamber in which a plasma arc is formed;
• providing a nozzle mounted relative to an electrode at a distal end of the torch body to define the plasma chamber, the nozzle comprising:
• a substantially hollow, elongated body capable of receiving the electrode, the nozzle body having a first end and a second end;
• a plasma exit orifice disposed at the first end of the nozzle body, wherein the length of the nozzle body from the first end to the second end is greater than about 2 inches;
• and
• at least one supplemental orifice disposed through at least one of an end face or a side wall of the nozzle, the at least one supplemental orifice relative to the plasma exit orifice;
• operating the plasma arc torch at an amperage level of at least about 15 Amps;
• and
• flowing substantially all cooling gas through the at least one gas outlet.

A method for extending the life of a plasma arc torch, the method comprising:

• providing a torch body which includes a plasma gas flow path for directing a plasma gas through a swirl ring to a plasma chamber in which a plasma arc is formed;
• providing a nozzle mounted relative to an electrode at a distal end of the torch body to define the plasma chamber, the nozzle comprising:
• a substantially hollow, elongated body capable of receiving the electrode, the nozzle body defining a longitudinal axis and having a length along the axis from a first end of the nozzle body to a second end of the nozzle body;
• and
• a plasma exit orifice disposed at the first end of the nozzle body,
• wherein the length of the nozzle body from the first end to the second end is greater than about 2 inches;
• operating the plasma arc torch at an amperage level of at least about 15 Amps;
• and flowing substantially all the cooling gas out the distal end of the torch body.