A composite plasma cutting electrode (500, 500'), comprising: a body portion (503, 503') made from a first material having a wall portion defining a cavity (507, 507') and a distal end having an distal end face and a first shoulder engagement portion (513, 515) which extends upstream from said distal end face, where said shoulder portion (513, 515) comprises first and second surfaces (510, 511); and a tip portion made from a second material, said tip portion having a distal end face and a tip cavity in said distal end face with an emissive insert disposed in said tip cavity, an upstream end face, and a second shoulder engagement portion extending downstream from said upstream end face having a first and second surface, and wherein said upstream end face of said tip portion makes physical contact with said first surface (510, 511) of said first shoulder engagement portion (513, 515); characterized in that said second surface of said first shoulder engagement portion (513, 515) is adjacent to said second surface of said second shoulder portion (513, 515) such that a first gap exists between said respective second surfaces, said first surface (510, 511) of said second shoulder engagement portion (513, 515) is adjacent to said distal end face of said body portion (503, 503') such that a second gap exists between said first surface (510, 511) of said second shoulder engagement portion (513, 515) and said distal end face of said body portion (503, 503'), and each of said first and second gaps are filled with a brazing material which secures said body portion (503, 503') is joined to said tip portion, and in that said second gap is larger than said first gap. a body portion (503, 503') made from a first material having a wall portion defining a cavity (507, 507') and a distal end having an distal end face and a first shoulder engagement portion (513, 515) which extends upstream from said distal end face, where said shoulder portion (513, 515) comprises first and second surfaces (510, 511); and a tip portion made from a second material, said tip portion having a distal end face and a tip cavity in said distal end face with an emissive insert disposed in said tip cavity, an upstream end face, and a second shoulder engagement portion extending downstream from said upstream end face having a first and second surface, and wherein said upstream end face of said tip portion makes physical contact with said first surface (510, 511) of said first shoulder engagement portion (513, 515); characterized in that said second surface of said first shoulder engagement portion (513, 515) is adjacent to said second surface of said second shoulder portion (513, 515) such that a first gap exists between said respective second surfaces, said first surface (510, 511) of said second shoulder engagement portion (513, 515) is adjacent to said distal end face of said body portion (503, 503') such that a second gap exists between said first surface (510, 511) of said second shoulder engagement portion (513, 515) and said distal end face of said body portion (503, 503'), and each of said first and second gaps are filled with a brazing material which secures said body portion (503, 503') is joined to said tip portion, and in that said second gap is larger than said first gap.