Hypertherm, Inc.

Zhipeng Lu

Richard W Couch, Jr

Charles Marcou Hackett

Nicholas A Sanders

Yong Yang

Lifeng Luo

John Sobr

Kenneth J Woods

Robert C Dean, Jr

David Jonathan Cook

Brian J Currier

William J Connally

Kirk H Ferland

Staffan C Stenfelt

Aaron D Brandt

Richard W Couch

Yutaka Nakano

Jennifer L Freeman

Elizabeth B Hackett

Jon W Lindsay

Stephen Theodore Eickhoff

Jeffrey L Peterson

Michael F Kornprobst

Norm LeBlanc

Patrik Backander

Timothy M Brewer

Young Yang

Roger L Kenyon

Nichols A Sanders

Charles M Hackett

A plasma arc torch that includes a torch body having a nozzle mounted relative to a composite electrode in the body to define a plasma chamber. The torch body includes a plasma flow path for directing a plasma gas to the plasma chamber in which a plasma arc is formed. The nozzle includes a hollow, body portion and a substantially solid, head portion defining an exit orifice. The composite electrode can be made of a metallic material (e.g., silver) with high thermal conductivity in the forward portion electrode body adjacent the emitting surface, and the aft portion of the electrode body is made of a second low cost, metallic material with good thermal and electrical conductivity. This composite electrode configuration produces an electrode with reduced electrode wear or pitting comparable to a silver electrode, for a price comparable to that of a copper electrode.

Composite electrode for a plasma arc torch

A metal jet cutting system, which includes a jetting heat, a heater and a power source, is used for modifying a workpiece. The jetting head includes a crucible and an inlet for receiving a feed stock of a conductive material. The heater melts the conductive material in the crucible to provide a conductive fluid, which exits the jetting head via an outlet. The power source, which is in electrical communication with the conductive fluid, increases the temperature of the conductive fluid. The conductive fluid is applied to the workpiece to modify the workpiece.

Process and apparatus for cutting or welding a workpiece

An output structure for material processing apparatus facilitates field replacement of consumable components, while maintaining important alignments. Contoured surfaces within the output structure mate with corresponding contoured surfaces on the consumable components, thereby facilitating alignment of the consumable components with an axis of the output structure. Material processing apparatus employing such surfaces include lasers and plasma arc torches and, with proper alignment, apparatus performance is improved. Typical consumable components include electrodes, swirl rings, nozzles, and shields. The consumable components can be axially translatable with respect to each other, thereby promoting contact starting of a plasma arc torch. An installation tool for consumable components also serves to align the components with an axis of the output structure.

Nozzle for plasma arc torch

Apparatus and method of improved consumable alignment in material processing apparatus

An electrode for use in a plasma arc torch has an insert designed to improve the service life of the electrode, particularly for high current processes. The electrode comprises an elongated electrode body formed of a high thermal conductivity material and having a bore disposed in a bottom end of the electrode body. The bore can be cylindrical or ring-shaped. An insert comprising a high thermionic emissivity material, and in some embodiments, a high thermal conductivity material, is disposed in the bore. The insert can be ringed-shaped or cylindrical.

Electrode for a plasma arc torch having an improved insert configuration

Disclosed is a novel method and structure for contact starting a plasma arc torch. A translatable, electrically conductive component such as a nozzle or swirl ring is biased into contact with an electrode by a compliant spring element. A pilot arc is formed by first passing current through the electrode/component interface. Thereafter, the component is translated under the influence of gas pressure in a plasma chamber formed between the electrode and component, compressing the compliant element and initiating the pilot arc. The spring element may be a separate element or may be maintained integrally with the nozzle, swirl ring, or a retaining cap, facilitating removal and replacement of the spring element with consumable components of the torch.

Plasma arc torch and method using blow forward contact starting system

Disclosed is a novel method and structure for contact starting a plasma arc torch. A translatable, electrically conductive component such as a nozzle or swirl ring is biased into contact with an electrode by a compliant spring element. A pilot arc is formed by first passing current through the electrode/component interface. Thereafter, the component is translated under the influence of gas pressure in a plasma chamber formed between the electrode and component, compressing the compliant element and initiating the pilot arc. The spring element may be maintained integrally with the nozzle, swirl ring, or a retaining cap, facilitating removal and replacement of the spring element with consumable components of the torch. Exemplary spring elements include wave spring washers, finger spring washers, curved spring washers, helical compression springs, flat wire compression springs, and slotted conical discs.

Integral spring consumables for plasma arc torch using blow forward

A translatable nozzle is supported in a contact start plasma arc torch at an aft end by a swirl ring and at a longitudinally spaced forward end by an insulative bearing member of a nozzle retainer. The nozzle is biased into contact with an electrode by a compliant spring element. A pilot arc is formed by first passing current through the electrode and nozzle. Upon pressurization of a plasma chamber formed therebetween, the nozzle is translated forward, compressing the spring element and initiating the pilot arc. The spring element may be maintained integrally with the nozzle to facilitate removal and replacement of the spring element with the consumable nozzle.

Blow forward contact start plasma arc torch with distributed nozzle

A plasma arc torch system includes a plasma arc torch and a positioning apparatus for automated processing of workpieces. In order to maintain consistent cut quality, a controller maintains arc voltage at a predetermined reference value by controlling a standoff between the torch and the workpiece. To prevent contact between the torch and workpiece during kerf crossings and to maintain an optimum standoff during acceleration and deceleration, standoff control override algorithms are implemented in the controller. Additionally, a contact sensing apparatus is provided to automatically retract the torch in the event of contact with the workpiece during processing.

Plasma arc torch position control

Disclosed is a method and structure for improving alignment of a plasma arc with an axial centerline of a plasma arc torch. At least one of an electrode and nozzle are mounted in respective bores of a cathode block and torch body using a radial spring element. By concentrically machining the bores along an axial centerline of the torch and centering the consumable components within the bores using the spring elements, an insert disposed in a tip of the electrode is axially aligned with an orifice formed in a tip of the nozzle. Asymmetric wear of the nozzle orifice due to a skewed arc path is markedly reduced or eliminated. The torch may be employed in computer controlled cutting and marking systems to produce components or workpieces with reduced dimensional and angular errors.

Apparatus and method for improved assembly concentricity in a plasma arc

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Hanover, NH, United States of America

Zhipeng Lu