Plasma arc torch

A plasma arc torch comprising:

• a torch head;
• a proximal anode member disposed within the torch head;
• a cathode disposed within the torch head;
• a central body disposed adjacent the torch head;
• and
• torch consumables disposed adjacent a distal end portion of the torch head, the torch consumables comprising:
• an electrode in electrical contact with the cathode and disposed within the central body;
• a tip disposed adjacent the electrode;
• a spacer disposed between the electrode and the tip;
• a baffle disposed around the central body;
• a distal anode member disposed between the central body and the baffle, the distal anode member in electrical contact with the tip;
• a central anode member disposed adjacent a proximal end portion of the distal anode member and in electrical contact with the distal anode member and the proximal anode member;
• a shield cap disposed around the baffle;
• a secondary cap disposed against an interior surface of the shield cap, the secondary cap comprising an interior portion defining a plurality of flutes;
• and
• a secondary spacer disposed between the tip and the secondary cap, wherein the plurality of flutes form a gas passageway between the secondary spacer and the secondary cap,
• wherein a plasma gas, a secondary gas, a cooling fluid, and current are conducted through the torch head, the central body, and torch consumables for operation of the plasma arc torch.

A plasma arc torch comprising:

• a torch head;
• a proximal anode member disposed within the torch head;
• a cathode disposed within the torch head;
• a central body disposed adjacent the torch head;
• and
• torch consumables disposed adjacent a distal end portion of the torch head, the torch consumables comprising:
• an electrode in electrical contact with the cathode and disposed within the central body;
• a tip disposed adjacent the electrode;
• a spacer disposed between the electrode and the tip;
• a baffle disposed around the central body;
• a distal anode member disposed between the central body and the baffle, the distal anode member in electrical contact with the tip;
• a central anode member disposed adjacent a proximal end portion of the distal anode member and in electrical contact with the distal anode member and the proximal anode member;
• a shield cap disposed around the baffle;
• a secondary cap disposed against an interior surface of the shield cap;
• and
• a secondary spacer disposed between the tip and the secondary cap, the secondary spacer comprising an exterior portion defining a plurality of flutes that form a gas passageway between the secondary spacer and the secondary cap,
• wherein a plasma gas, a secondary gas, a cooling fluid, and current are conducted through the torch head, the central body, and torch consumables for operation of the plasma arc torch.

A plasma arc torch comprising:

• a torch head;
• a proximal anode member disposed within the torch head;
• a cathode disposed within the torch head;
• a central body disposed adjacent the torch head;
• and
• torch consumables disposed adjacent a distal end portion of the torch head, the torch consumables comprising:
• an electrode in electrical contact with the cathode and disposed within the central body;
• a tip disposed adjacent the electrode;
• a spacer disposed between the electrode and the tip;
• a baffle disposed around the central body;
• a distal anode member disposed between the central body and the
• baffle, the distal anode member in electrical contact with the tip;
• a central anode member disposed adjacent a proximal end portion of the distal anode member and in electrical contact with the distal anode member and the proximal anode member;
• a shield cap disposed around the baffle;
• a secondary cap disposed against an interior surface of the shield cap;
• and
• a secondary spacer disposed between the tip and the secondary cap, the secondary spacer comprising a plurality of crenulations at a proximal end portion,
• wherein a plasma gas, a secondary gas, a cooling fluid, and current are conducted through the torch head, the central body, and torch consumables for operation of the plasma arc torch.

A secondary cap for use in a plasma arc torch comprising:

• a plurality of crenulations formed around a proximal end portion;
• and
• a plurality of flutes formed along an interior portion,
• wherein the secondary cap is disposed between a tip and a shield cap of the plasma arc torch and the crenulations and flutes form gas passageways between the secondary cap and adjacent components of the plasma arc torch for the flow of a secondary gas.

A secondary spacer for use in a plasma arc torch comprising:

• a plurality of crenulations formed around a proximal end portion;
• and
• a plurality of flutes formed along an exterior portion,
• wherein the secondary spacer is disposed between a tip and a shield cap of the plasma arc torch and the crenulations and flutes form gas passageways between the secondary spacer and adjacent components of the plasma arc torch for the flow of a secondary gas.