Apparatus for proper alignment of components in a plasma arc torch

A plasma arc torch, comprising:

• a electrode having a longitudinally extending connection end;
• a cathode body in a coaxial relationship with said electrode, said cathode body having a bore defined therein into which said electrode connection end extends, said bore including a contact surface defined substantially perpendicular to a longitudinal axis of said torch and a threaded section;
• said electrode connection end comprising a contact shoulder defined substantially perpendicular to the longitudinal axis of said torch, a threaded engagement section configured to engage with said threaded section of said cathode body to draw said contact shoulder against said contact surface, and an alignment section extending rearwardly from said threaded section;
• and
• said alignment section having a diameter closely matching that of said bore such that axial misalignment between said electrode and said cathode body is minimized.

An electrode component for use in a plasma arc torch, said electrode comprising:

• an insert end and an opposite connection end;
• said connection end insertable into a bore in a cathode body and comprising a contact shoulder defined substantially perpendicular to a longitudinal axis of said torch, a threaded engagement section disposed rearwardly of said contact shoulder and configured to engage with a corresponding threaded section of the cathode body, and a longitudinally extending alignment section extending rearwardly from said threaded section;
• and
• wherein said alignment section has a diameter less than that of said threaded section and closely matching that of the cathode body bore such that when said electrode is inserted into the cathode body, axial misalignment between said electrode and said cathode body is minimized.