Plasma gas distributor with integral metering and flow passageways

A plasma arc torch comprising:

• an electrode;
• a tip;
• and
• a gas distributor disposed between the electrode and the tip, the gas distributor comprising:
• a body defining a proximal end portion and a distal end portion;
• at least one plasma gas passageway formed in the proximal end portion;
• at least one metering passageway formed conjointly with the plasma gas passageway;
• and
• at least one helical gas passageway formed along an interior portion of the body, the helical gas passageway being in fluid communication with the plasma gas passageway and the metering passageway.

A plasma arc torch comprising:

• an electrode;
• a tip;
• a gas distributor disposed between the electrode and the tip to define a plasma arc chamber therebetween, the gas distributor comprising a helical gas passageway formed along an interior portion of the body;
• a plasma gas passageway disposed proximally from the plasma arc chamber to provide a supply of plasma gas to the plasma arc chamber;
• and
• a flow metering device disposed within the plasma gas passageway and in fluid communication with the helical gas passageway.

A gas distributor for use in a plasma arc torch comprising:

• a body defining a proximal end portion and a distal end portion;
• at least one plasma gas passageway formed in the proximal end portion;
• and
• at least one helical gas passageway formed along an interior portion of the body and in fluid communication with the plasma gas passageway, the helical gas passageway defining at least one groove having a smaller size towards the proximal end portion and a larger size towards the distal end portion.

A method of operating a plasma arc torch, the method comprising the steps of:

• directing a flow of plasma gas through at least one plasma gas passageway;
• successively directing the flow of plasma gas through at least one metering passageway such that a flow rate of the plasma gas is reduced;
• and
• successively directing the reduced flow rate plasma gas through a helical gas passageway within a gas distributor.