Cooling plasma cutting system consumables and related systems and methods

An electrode for a plasma cutting system, the electrode comprising:

• an arc portion shaped to matingly engage a nozzle of the plasma cutting system, the arc portion having a first end comprising a plasma arc emitter disposed at a distal end thereof;
• and
• a thermal portion in thermal communication with a second end of the arc portion, the thermal portion shaped to slidingly engage a complementary swirl ring of the plasma cutting system and including:
• a first circumferentially formed disk-shaped flange mating feature extending radially from a proximal end of the thermal portion of the electrode, the first circumferentially formed disk shaped flange mating feature defining a first radial width to physically mate with the swirl ring, the first circumferentially formed disk-shaped flange mating feature including a sealing member adapted to form a dynamic seal with the swirl ring to prevent a gas from traveling proximally between the electrode and the swirl ring,
• a second circumferentially formed disk-shaped flange mating feature extending radially from a distal end of the thermal portion of the electrode to define a second radial width to physically mate with the swirl ring, wherein the first radial width and the second radial width are substantially equal, and
• a thermal exchange surface region between the first disk-shaped flange mating feature and the second disk-shaped flange mating feature, the thermal exchange surface defining at least one annular flange extending from the thermal portion between the first circumferentially formed disk-shaped flange mating feature and the second circumferentially formed disk-shaped flange mating feature, the at least one annular flange having a radial width less than at least one of the first radial width and the second radial width.