Apparatus and method of aligning and securing components of a liquid cooled plasma arc torch and improved torch design

A plasma arc torch, comprising:

• a cathode adaptor body having at least two first sealant channels formed on an outer surface of a first end of the cathode adaptor body to respectively accept at least two first sealant rings, the at least two first sealant channels are spaced apart from each other by a first distance that is in a range of 2 percent to 90 percent of an overall length of the cathode adaptor body;
• a cathode body coupled to a second end of the cathode adaptor body, the cathode body having at least two second sealant channels formed on an outer surface of the cathode body to respectively accept at least two second sealant rings, the at least two second sealant channels are spaced apart from each other by a second distance that is in a range of 2 percent to 50 percent of an overall length of the cathode body;
• a pilot arc connector having at least two third sealant channels formed on an outer surface of the pilot arc connector to respectively accept at least two third sealant rings, the at least two third sealant channels are spaced apart from each other by a third distance that is in a range of 2 percent to 90 percent of an overall length of the pilot arc connector;
• and
• a rear isolator that isolates the cathode body from an anode body, the rear isolator having
• at least two fourth sealant channels formed on an outer surface of the rear isolator to respectively accept at least two fourth sealant rings, the at least two fourth sealant rings engaging with an inner surface of the anode body and the at least two fourth sealant channels are spaced apart from each other by a fourth distance that is in a range of 2 percent to 50 percent of an overall length of the rear isolator, and
• at least two fifth sealant channels formed on the outer surface of the rear isolator to respectively accept at least two fifth sealant rings, the at least two fifth sealant rings engaging with an inner surface of a ring isolator and the at least two fifth sealant channels are spaced apart from each other by a fifth distance that is in a range of 2 percent to 50 percent of the overall length of the rear isolator.