Patent Description:
Thermal processing torches, such as plasma arc torches, are widely used in the heating, cutting, gouging and marking of materials. A plasma arc torch generally includes an electrode, a nozzle having a central exit orifice mounted within a torch body, electrical connections, passages for cooling, and passages for arc control fluids (e.g., plasma gas). Optionally, a swirl ring is employed to control fluid flow patterns in the plasma chamber formed between the electrode and the nozzle. In some torches, a retaining cap can be used to maintain the nozzle and/or swirl ring in the plasma arc torch. In operation, the torch produces a plasma arc, which is a constricted jet of an ionized gas with high temperature and sufficient momentum to assist with removal of molten metal.

Gouging of conductive (e.g., metallic) materials is often needed for a number of material processing applications and products. These gouges typically form troughs/channels in the workpiece by removing materials to a certain desired depth. A gouging process can also be used to remove welds that contain known process defects or fractures. In today's gouging operations with typical plasma arc torches having a circular bore, the width of a gouge is limited by plasma processing, such as by standoff, amperage, and process speed. Thus, to make a wider gouge, a traditional plasma arc torch needs to pass over a workpiece a number of times, essentially forming a series of connected channels with similar depth. Further, some operators and systems oscillate the torch during gouge processing to widen the affected area while maintaining depth control. However, repeated torch passing and/or torch oscillation are like to produce inconsistent surface textures (e.g., scalloped and/or ribbed features), require skilled operators and/or complex machinery to achieve, and be time consuming. Even though automated torch oscillation may minimize surface texture variations, it greatly increases processing time because high oscillation to low linear travel speed ratio is often needed to avoid the variations. <CIT> discloses a consumable set that is usable in a plasma arc torch to direct a plasma arc to a processing surface of a workpiece. The consumable set includes a nozzle having: <NUM>) a nozzle body defining a longitudinal axis extending therethrough, and <NUM>) a nozzle exit orifice, disposed in the nozzle body, for constricting the plasma arc. The nozzle exit orifice defines an exit orifice axis oriented at a non-zero angle relative to the longitudinal axis. The consumable set can also include an alignment surface generally parallel to the exit orifice axis. The alignment surface is dimensioned to align the exit orifice such that the plasma arc impinges orthogonally on the processing surface. <CIT> discloses a consumable set that is usable in a plasma arc torch to direct a plasma arc to a processing surface of a workpiece. The consumable set comprises a nozzle and an alignment surface. The nozzle includes: <NUM>) a nozzle body defining a longitudinal axis extending therethrough, and <NUM>) a nozzle exit orifice disposed in the nozzle body for constricting the plasma arc. The nozzle exit orifice defines an exit orifice axis oriented at a non-zero bevel angle relative to the longitudinal axis. The alignment surface is generally parallel to the longitudinal axis and substantially planar. The alignment surface is dimensioned to orient the nozzle exit orifice such that the plasma arc impinges on the processing surface of the workpiece at the bevel angle while the plasma arc torch is substantially perpendicular to the processing surface.

Therefore, there is a need to design torches and torch consumables that can produce a wide gouge profile in the workpiece (e.g., the width substantially greater than the depth) during a single pass of the torch over the workpiece and/or without torch oscillation.

The present invention provides a torch tip assembly design that allows a gouge profile to be created in the workpiece having a width substantially wider than its depth (e.g., greater than about a <NUM>-to-<NUM> ratio) from a single-pass gouge operation and/or without oscillation. The torch tip assembly can include a non-circular bore and/or a non-circular counter bore feature positioned at specific orientations to achieve the desired gouge profile.

In one aspect, the present invention provides a consumable tip for a plasma arc torch according to claim <NUM>.

In another aspect, the invention provides a method for assembling at least a portion of a plasma arc torch according to claim <NUM>.

Advantageous embodiments are provided in the dependent claims.

It should also be understood that various aspects and embodiments of the invention can be combined in various ways. Based on the teachings of this specification, a person of ordinary skill in the art can readily determine how to combine these various embodiments. For example, in some embodiments, any of the aspects above can include one or more of the above features. One embodiment of the invention can provide all of the above features and advantages.

The advantages of the invention described above, together with further advantages, may be better understood by referring to the following description taken in conjunction with the accompanying drawings.

<FIG> shows an exemplary plasma arc torch <NUM> for cutting a workpiece. The plasma arc torch <NUM> includes a torch body <NUM> and a torch tip <NUM>. The torch tip <NUM> includes multiple consumables, for example, an electrode <NUM>, a nozzle <NUM>, a retaining cap <NUM> and a swirl ring <NUM>. The torch tip <NUM> can also include a shield (not shown). The torch body <NUM>, which has a generally cylindrical shape, supports the electrode <NUM> and the nozzle <NUM>. The nozzle <NUM> is spaced from the electrode <NUM> and has a central exit orifice <NUM> mounted within the torch body <NUM>. The swirl ring <NUM> is mounted to the torch body <NUM> and has a set of radially offset or canted gas distribution holes <NUM> that impart a tangential velocity component to the plasma gas flow, causing the plasma gas flow to swirl. If a shield is present, the shield includes a shield exit orifice and is connected (e.g., threaded) to the retaining cap <NUM>. The retaining cap <NUM> as shown is an inner retaining cap securely connected (e.g., threaded) to the torch body <NUM>. An outer retaining cap (not shown) may be secured relative to the shield. The torch <NUM> can additionally include electrical connections, passages for cooling, passages for arc control fluids (e.g., plasma gas), and a power supply. The consumables can include a welding tip, which is a nozzle for passing an ignited welding gas.

In operation, a plasma gas flows through a gas inlet tube (not shown) and the gas distribution holes <NUM> in the swirl ring <NUM>. From there, the plasma gas flows into a plasma chamber <NUM> and out of the torch <NUM> through the exit orifice <NUM> of the nozzle <NUM> that constricts the plasma gas flow. A pilot arc is first generated between the electrode <NUM> and the nozzle <NUM>. The pilot arc ionizes the gas passing through the nozzle exit orifice <NUM>. The arc then transfers from the nozzle <NUM> to a workpiece <NUM> for thermally processing (e.g., cutting or welding) the workpiece <NUM>. The nozzle <NUM> may be suitably configured to be positioned as close as possible to an inner corner of the workpiece <NUM> created by a protruding flange <NUM> and a horizontal portion <NUM>. The nozzle <NUM> can guide a plasma gas flow through the exit orifice <NUM> such that the plasma gas impinges orthogonally on the flange <NUM> as the plasma gas exits from the orifice <NUM>, thereby cutting the flange <NUM> from the workpiece <NUM> along the path <NUM>. It is noted that the illustrated details of the torch <NUM>, including the arrangement of the components, the direction of gas and cooling fluid flows, and the electrical connections, can take a variety of forms. In addition, even though the flange <NUM> and the horizontal portion <NUM> of the inner corner are illustrated as being perpendicular to each other, the two portions of the workpiece <NUM> can be oriented at any angle and the nozzle <NUM> can be suitably configured to perform flush cutting in the resulting inner corner.

<FIG> show various perspectives of an exemplary configuration of the nozzle <NUM> designed to facilitate inner-corner flush cutting operations. The nozzle <NUM> includes a nozzle body <NUM> defining a longitudinal axis A extending therethrough. An interior surface <NUM> of the nozzle <NUM> can be rotationally symmetrical about the longitudinal axis A while the exterior of the nozzle body <NUM> is rotationally asymmetric about the longitudinal axis A. The nozzle exit orifice <NUM>, disposed in the nozzle body <NUM>, defines an exit orifice axis B extending longitudinally along the length of the nozzle exit orifice <NUM> from an interior opening 225b to an exterior opening 225a. The exit orifice axis B is oriented at a non-zero angle relative to the longitudinal axis A. That is, the nozzle exit orifice <NUM> can be rotationally asymmetric about the longitudinal axis A. The nozzle exit orifice <NUM> is configured to introduce a plasma arc flow from the interior opening 225b, which is in fluid communication with the interior surface <NUM> of the nozzle <NUM>, to a workpiece through the exterior opening 225a. Even though the nozzle exit orifice <NUM> is shown as being substantially straight, the nozzle exit orifice <NUM> can be curved or have a sequence of non-parallel segments.

In addition, the nozzle <NUM> includes an alignment surface <NUM> disposed on the exterior surface of the nozzle body <NUM>. The alignment surface <NUM> can be generally parallel to the exit orifice axis B, such as exactly parallel to the exit orifice axis B or within about <NUM> degrees from being parallel to the exit orifice axis B. During torch operation, the alignment surface <NUM> is dimensioned to lay substantially flush against a guiding surface <NUM> on the horizontal portion <NUM> of the workpiece <NUM>, which is a surface that is not being cut by the plasma arc and is used instead to guide and/or position the torch for enhanced flush cutting of the flange <NUM>. Specifically, the alignment surface <NUM> of the nozzle <NUM>, upon being laid upon the guiding surface <NUM> of the horizontal portion <NUM>, aligns the external end 225a of the nozzle exit orifice <NUM> against the processing surface <NUM> of the flange <NUM> such that a plasma arc impinges orthogonally onto the processing surface <NUM> and into the flange <NUM> along the cut path <NUM>. The longitudinal axis A of the nozzle body may be oriented at an acute angle relative to the alignment surface <NUM>, such as at a <NUM>-degree angle relative to the alignment surface <NUM>. As shown in <FIG>, the processing surface <NUM> and the guiding surface <NUM> of the workpiece <NUM> are angled relative to each other to form the inner corner of the workpiece <NUM>. Even though the guiding surface <NUM> is illustrated as a portion of the workpiece <NUM>, the guiding surface <NUM> may be a portion of a separate template (not shown) used to guide the torch <NUM> into position. For example, the separate template, which includes the guiding surface <NUM>, can be attached to the torch <NUM> and/or the workpiece <NUM> for positioning the torch <NUM> to perform flush cutting.

A distance <NUM> between the center of the exterior opening 225a of the nozzle exit orifice <NUM> and the alignment surface <NUM> may be less than or equal to about <NUM>, <NUM>, <NUM> ( <NUM> inches, <NUM> inches, or <NUM> inches). This distance controls how close the cut path <NUM> is to the horizontal portion <NUM> of the workpiece <NUM>. Hence, the smaller the distance <NUM>, the closer the plasma arc torch cuts to the base of the flange <NUM> from the horizontal portion <NUM>.

In addition to the (first) alignment surface <NUM>, the nozzle <NUM> can also include a second alignment surface <NUM> angled relative to the alignment surface <NUM> and a curved surface <NUM> that interconnects the two alignment surfaces. During torch operation, the second alignment surface <NUM>, in cooperation with the alignment surface <NUM>, enhances orthogonal impingement of the plasma arc against the processing surface <NUM> of the flange <NUM>. For example, the second alignment surface <NUM> can be oriented at an angle from the alignment surface <NUM> such that the second alignment surface <NUM> lays substantially flush against the processing surface <NUM> of the flange <NUM> while the alignment surface <NUM> lays substantially flush against the guiding surface <NUM> of the horizontal portion <NUM>. In addition, the curved surface <NUM> of the nozzle <NUM> is configured to inter-fit within the corner created by the processing surface <NUM> and the guiding surface <NUM> of the workpiece <NUM>. The two alignment surfaces of the nozzle <NUM> ensure that the plasma arc torch is positioned tightly and securely into the inner corner of the workpiece <NUM> while a plasma arc is delivered to the processing surface <NUM> by the torch <NUM> via the exterior opening 225a of the nozzle exit orifice <NUM>. As shown in <FIG>, the exterior opening 225a of the nozzle exit orifice <NUM> is located on the second alignment surface <NUM> of the nozzle <NUM>.

In some examples, the first alignment surface <NUM> and the second alignment surface <NUM> are substantially perpendicular to each other such that the nozzle <NUM> can be securely positioned into an inner corner of about <NUM> degrees. In other examples, nozzles with different angles between the alignment surfaces (e.g., <NUM> degrees, 30degrees and <NUM> degrees) can be constructed such that an operator can choose the most appropriate nozzle to perform flush cutting in view of the angle of a given inner corner. The angle between the first alignment surface <NUM> and the second alignment surface <NUM> of a nozzle <NUM> may be adjustable, such that the operator can adjust one or both of the alignment surfaces to produce a secure fit of the nozzle <NUM> into any given corner of a workpiece. For example, adjustments can be made such that both of the alignment surfaces of the nozzle <NUM> can contact respect processing surface <NUM> and guiding surface <NUM> of the workpiece <NUM> during a cutting operation.

Another approach for illustrating the asymmetric nature of the nozzle <NUM> is shown in <FIG>. A plane can be defined to include the exit orifice axis B, thereby segmenting the nozzle <NUM> into two portions: <NUM>) a first, smaller portion <NUM> on one side of plane and <NUM>) a second, larger portion <NUM> on the other side of the plane. The alignment surface <NUM> of the nozzle <NUM> is located on the external surface of the first portion <NUM> and can contact the guiding surface <NUM> of the workpiece once the torch <NUM> is positioned into the inner corner of the workpiece. The second alignment surface <NUM> is located on the external surface of the second portion <NUM> and can contact the processing surface <NUM> of the workpiece during a cutting operation. The first portion <NUM> can be about <NUM>/<NUM>, <NUM>/<NUM>, or <NUM>/<NUM> of the volume of the second portion <NUM>.

The contour of the alignment surface <NUM> of the nozzle <NUM> may have at least a rounded-arc portion <NUM>, as shown from a top view of the nozzle <NUM> in <FIG>. The rounded-arc portion <NUM> can be positioned in an inner corner created by the intersection of a horizontal portion <NUM> and a flange <NUM> of a workpiece <NUM>. The distance from a first point <NUM> on the rounded-arc portion <NUM> to the center of the exterior opening 225a of the nozzle exit orifice <NUM> is at least substantially equal to the distance from a second point <NUM> on the rounded-arc portion <NUM> to the center of the exterior opening 225a. The exterior opening 225a can be located on a second alignment surface <NUM> of the nozzle <NUM>. Such equidistance configuration ensures that an operator of the plasma arc torch can predict the location on the workpiece to which a plasma arc would be delivered prior to initiating the plasma arc operation, thereby allowing the cutting operation to be repeatable and predictable. The second alignment surface <NUM> may be designed to include a similar rounded-arc portion.

<FIG> show various perspectives of another exemplary nozzle <NUM> that includes three alignment surfaces. Specifically, the nozzle <NUM> includes i) a (first) alignment surface <NUM>, ii) a second alignment surface <NUM> angled relative to the alignment surface <NUM>, iii) a third alignment surface <NUM> angled relative to the alignment surface <NUM> and the second alignment surface <NUM>; and iv) one or more curved surfaces <NUM> connecting the three alignment surfaces. The nozzle <NUM> is configured to perform flush cutting in relation to an inner corner of a workpiece <NUM> constructed from three surfaces, with the surface being cut referred to as the processing surface and the remaining two surfaces referred to as the guiding surfaces. In other examples, the guiding surfaces are disposed on one or more separate templates that are attachable to the workpiece <NUM> and/or the nozzle <NUM>. In operation, the three alignment surfaces of the nozzle <NUM>, in cooperation with each other, align the plasma arc to impinge orthogonally on the processing surface of the workpiece <NUM>. For example, the alignment surfaces <NUM> and <NUM> can lay substantially flush against the two guiding surfaces of the workpiece <NUM> while the alignment surface <NUM>, which includes the exterior opening 225a of the nozzle exit orifice <NUM>, lays substantially flush against the processing surface of the workpiece <NUM>. The alignment surfaces of the nozzle <NUM> ensure that the plasma arc torch is positioned tightly and securely into the inner corner of the workpiece <NUM> while a plasma arc is delivered to the processing surface of the workpiece <NUM> via the exterior opening 225a. In some examples, at least one of the alignment surface <NUM>, the second alignment surface <NUM>, or the third alignment surface <NUM> has a contour with a rounded-arc portion, similar to the contour illustrated in <FIG>.

The asymmetric design described with respect to <FIG> can be introduced to a plasma arc torch that includes a shield. The shield can include at least one of the alignment surface <NUM> or the second alignment surface <NUM> describe above with respect to the nozzle <NUM>. In alternative examples, the shield can include at least one of the alignment surface <NUM>, the second alignment surface <NUM>, or the third alignment surface <NUM> describe above with respect to the nozzle <NUM>. The asymmetric shield can further include a shield exit orifice coplanar with the nozzle exit orifice for delivering the plasma arc to impinge on a processing surface of a workpiece. The asymmetric shield, upon installation into a plasma arc torch, can provide similar functions as the asymmetric nozzle <NUM> or <NUM>, such as allowing an operator to securely and tightly position the torch into an inner corner of a workpiece created by two or three workpiece surfaces, while the torch delivers a plasma arc flow to one of the workpiece surfaces. The contour of at least one of the alignment surfaces of the asymmetric shield has a rounded-arc portion, similar to the contour illustrated in <FIG>.

A plasma arc torch with a nozzle may be provided for making a bevel cut on a workpiece. The torch can remain perpendicular (e.g., at a fixed <NUM> degree angle) to the workpiece during the cut operation. Hence, the bevel feature is provided by the nozzle itself, rather than the angularity of the torch. A template can be provided to guide the torch, which is useful in situations where an operator desires to make the bevel cut at a consistent angle over a distance. The plasma arc torch of the present technology can improve the quality of bevel cuts, thereby decreasing the need for secondary processing work or accessories.

<FIG> shows an exemplary plasma arc torch for cutting a workpiece at a bevel angle. The plasma arc torch <NUM> includes a torch body <NUM> and a torch tip <NUM>. The torch tip <NUM> includes multiple consumables, for example, an electrode <NUM>, a nozzle <NUM>, a retaining cap <NUM> and a swirl ring <NUM>. The torch tip <NUM> can also include a shield (not shown). The function and configuration of many components of the torch <NUM>, including the electrode <NUM>, retaining cap <NUM> and swirl ring <NUM>, can be substantially similar to the counterpart components of the plasma torch <NUM> of <FIG>.

As shown in <FIG>, the nozzle <NUM> is mounted within the torch body <NUM> in a spaced relationship from the electrode <NUM>. The nozzle <NUM> has a body defining a longitudinal axis <NUM> extending therethrough and an exit orifice <NUM>. In operation, a plasma gas flows out of the torch <NUM> through the exit orifice <NUM> configured to constrict the plasma gas flow. A pilot arc is first generated between the electrode <NUM> and the nozzle <NUM>. The pilot arc ionizes the gas passing through the nozzle exit orifice <NUM>. The arc then transfers from the nozzle <NUM> to a workpiece <NUM> for thermally processing (e.g., cutting) the workpiece <NUM>. The nozzle <NUM> may be suitably configured to allow the torch <NUM> to be positioned substantially perpendicular to a processing surface <NUM> of the workpiece <NUM>, where the processing surface <NUM> is defined as a substantially flat surface on the workpiece <NUM> on which the plasma arc delivered by the torch <NUM> makes the initial contact. Specifically, the nozzle <NUM> can guide a plasma gas flow through the exit orifice <NUM> such that the plasma gas impinges on the processing surface <NUM> at a bevel angle <NUM> relative to the longitudinal axis <NUM> of the nozzle <NUM>, while the torch <NUM> remains substantially perpendicular to the processing surface <NUM>. This operation cuts the workpiece <NUM> into two pieces along the path <NUM>. A template <NUM> may be used to guide and/or position the torch <NUM> for enhanced bevel cutting of the workpiece <NUM>, especially over a distance along a lengthwise direction <NUM> of the workpiece <NUM>.

<FIG> show various perspectives of an exemplary configuration of the nozzle <NUM> designed to facilitate bevel cutting. The nozzle <NUM> includes a nozzle body <NUM> defining the longitudinal axis <NUM> extending therethrough. An interior surface <NUM> of the nozzle <NUM> can be rotationally symmetrical about the longitudinal axis <NUM>. The nozzle exit orifice <NUM>, disposed in the nozzle body <NUM>, defines an exit orifice axis <NUM> extending longitudinally along the length of the nozzle exit orifice <NUM> from an interior opening 425b to an exterior opening 425a. The exit orifice axis <NUM> can be oriented at a non-zero bevel angle <NUM> relative to the longitudinal axis <NUM>. That is, the nozzle exit orifice <NUM> can be rotationally asymmetric about the longitudinal axis <NUM>. The non-zero bevel angle <NUM> can be between about <NUM> degree and ± <NUM> degrees relative to the longitudinal axis <NUM>, such as between about <NUM> and about <NUM> degrees relative to the longitudinal axis <NUM>. An exemplary bevel angle <NUM> can be <NUM>, <NUM> or <NUM> degrees. The nozzle exit orifice <NUM> is configured to introduce a plasma arc flow from the interior opening 425b, which is in fluid communication with the interior surface <NUM> of the nozzle <NUM>, to a workpiece through the exterior opening 425a to cut the workpiece at the non-zero bevel angle <NUM>. Even though the nozzle exit orifice <NUM> is shown as being substantially straight, the nozzle exit orifice <NUM> can be curved or have a sequence of non-parallel segments.

In addition, the nozzle <NUM> includes an alignment surface <NUM> disposed on the exterior surface of the nozzle body <NUM>. The alignment surface <NUM> can be generally parallel to the longitudinal axis <NUM>, such as exactly parallel to the longitudinal axis <NUM> or within about <NUM> degrees from being parallel to the longitudinal axis <NUM>. The alignment surface <NUM> can be substantially planar. A distance <NUM> between the center of the exterior opening 425a of the nozzle exit orifice <NUM> and the alignment surface <NUM> may be less than or equal to about <NUM>, <NUM>, <NUM> ( <NUM> inches, <NUM> inches, or <NUM> inches).

During an exemplary torch operation, the alignment surface <NUM> is dimensioned to slidingly contact (e.g., lay substantially flush against) a guiding surface <NUM> on the template <NUM>, which is a surface used to guide and/or position the torch <NUM> for more precise bevel cutting of the workpiece <NUM>, as shown in <FIG>. Specifically, the alignment surface <NUM> of the nozzle <NUM>, upon contacting (e.g., being laid flush against) the guiding surface <NUM> of the template <NUM>, is adapted to orient the plasma arc torch <NUM> substantially perpendicular to the processing surface <NUM> of the workpiece <NUM> such that the external opening 425a of the nozzle exit orifice <NUM> is aligned against the processing surface <NUM> of the workpiece <NUM> to introduce a plasma arc that impinges onto the processing surface <NUM> at the bevel angle <NUM> along the cut path <NUM>.

The guiding surface <NUM> of the template <NUM> may extend along the lengthwise direction <NUM> for a specific distance such that an operator can slide the torch <NUM> against the guiding surface <NUM> in the lengthwise direction <NUM> to make a bevel cut at a consistent angle over the distance. The guiding surface <NUM> of the template <NUM> and/or the alignment surface <NUM> of the torch <NUM> may include a set of bearings (not shown) to facilitate the sliding contact between the two surfaces, such as to reduce the amount of friction between the two surfaces. The template <NUM> can be attached to or integrally constructed with/from workpiece <NUM> or the torch <NUM>. The template <NUM> can also be a separate, stand-alone component.

In addition to the (first) alignment surface <NUM>, the nozzle <NUM> can also include a second alignment surface <NUM> substantially perpendicular to the alignment surface <NUM> and a curved surface <NUM> that interconnects the two alignment surfaces. The curved surface <NUM> may be absent and the alignment surfaces <NUM>, <NUM> may be perpendicularly connected to each other. During torch operation, the second alignment surface <NUM>, in cooperation with the alignment surface <NUM>, enhances impingement of the plasma arc against the processing surface <NUM> of the workpiece <NUM> at the bevel angle <NUM>. For example, the second alignment surface <NUM> can be oriented perpendicular to the alignment surface <NUM> such that the second alignment surface <NUM> contacts the processing surface <NUM> of the workpiece <NUM> while the alignment surface <NUM> contacts the guiding surface <NUM> of the template <NUM>. The second alignment surface <NUM> can lay substantially flush against (i.e., parallel to) the processing surface <NUM> and substantially perpendicular to the longitudinal axis <NUM> of the nozzle <NUM>. The two alignment surfaces of the nozzle <NUM> ensure that the plasma arc torch <NUM> is positioned substantially perpendicularly against the processing surface <NUM> of the workpiece <NUM> while a plasma arc is delivered to the processing surface <NUM> by the torch <NUM> via the exterior opening 425a of the nozzle exit orifice <NUM> at the bevel angle <NUM>. As shown in <FIG>, the exterior opening 425a of the nozzle exit orifice <NUM> is located on the second alignment surface <NUM> of the nozzle <NUM>.

The contour of the second alignment surface <NUM> of the nozzle <NUM> may be asymmetric, including at least a rounded-arc portion <NUM> and a straight portion <NUM>, as shown from a top view of the nozzle <NUM> in <FIG>. The straight portion <NUM> can be located on a side of the second alignment surface <NUM> close to the alignment surface <NUM>. In operation, the straight portion <NUM> can be positioned substantially parallel to the guiding surface <NUM> of the template <NUM> so as to be guided by the template <NUM> during cutting. The nozzle exit orifice <NUM> can be angled such that the plasma arc path <NUM> is directed toward the straight portion <NUM> (i.e., the alignment surface <NUM>) as the plasma arc exits the exterior opening 425a located on the second alignment surface <NUM>. The exterior opening 425a may be located off-centered on the second alignment surface <NUM> (i.e., closer to the straight portion <NUM> than to the rounded-arc portion <NUM>). This off-centered feature allows the plasma arc to be more easily imparted at a bevel angle closer to the straight portion <NUM>. In contrast, the interior opening 425b (as shown in <FIG>) can be centered relative to the nozzle body <NUM> so as to align with the hafnium insert <NUM> in the electrode <NUM>. The use of the template <NUM> may be optional. When the second alignment surface <NUM> allows the plasma arc torch <NUM> to be more easily and securely positioned perpendicular to the processing surface <NUM> of the workpiece <NUM>, the template <NUM> may not be needed, especially if the distance of the bevel cut in the lengthwise direction <NUM> is relatively short.

<FIG> shows another exemplary nozzle <NUM> that includes three alignment surfaces. Specifically, the nozzle <NUM> includes i) a (first) planar alignment surface <NUM>, ii) a second planar alignment surface <NUM> oriented substantially perpendicular to the alignment surface <NUM> and adapted to contact the processing surface <NUM> of the workpiece <NUM> during torch operation, iii) a third planar alignment surface <NUM> that is oriented substantially perpendicularly to the second alignment surface <NUM> and substantially parallel to the alignment surface <NUM>, and iv) two arced surfaces <NUM> and <NUM>. The planar alignment surface <NUM> functions similar to the alignment surface <NUM> of the nozzle <NUM>. Specifically, the alignment surface <NUM> is configured to slidingly contact a first template (not shown) to position the torch while a plasma arc is directed along a cut path <NUM> toward the alignment surface <NUM>. The second alignment surface <NUM> functions substantially similar to the second alignment surface <NUM> of the nozzle <NUM>. Specifically, it is configured to contact the processing surface <NUM> of the workpiece <NUM>, so as to lay substantially parallel over the workpiece <NUM> perpendicular to a longitudinal axis <NUM> of the nozzle <NUM>, while the plasma arc is delivered via an exterior opening <NUM> located on the second alignment surface <NUM>. The contour of the second alignment surface <NUM> can be substantially symmetrical. The third alignment surface <NUM> is configured to slidingly contact a second template (not shown) for positioning the torch while the plasma arc is directed along the cut path <NUM> away from the third alignment surface <NUM>. In operation, the three alignment surfaces of the nozzle <NUM>, in cooperation with each other, align the plasma arc to impinge on the processing surface of the workpiece at a bevel angle. For example, the alignment surfaces <NUM> and <NUM> can lay substantially flush against two templates while the alignment surface <NUM>, which includes the exterior opening <NUM> of the nozzle exit orifice, lays substantially flush against the processing surface of the workpiece. The alignment surfaces of the nozzle <NUM> ensure that the plasma arc torch is positioned substantially perpendicularly to the workpiece while a plasma arc is delivered to the processing surface via the exterior opening <NUM>.

An operator may use both the first and second templates to achieve precise positioning of the nozzle <NUM> as he makes a cut on the workpiece along the lengthwise direction. The first and second templates can be attached to each other such that they can be positioned around the nozzle simultaneously. Only one template may be used, in cooperation with either the alignment surface <NUM> or the second alignment surface <NUM>, to guide the plasma arc to impinge toward or away from the template. For example, the operator can use only the first template positioned against the alignment surface <NUM> to guide the nozzle <NUM> as it cuts in the lengthwise direction toward the template. The operator may use only the second template positioned against the alignment surface <NUM> to guide to nozzle <NUM> as it cuts in the lengthwise direction away from the second template. The operator may not use a template when making a bevel, especially if the cut distance in the lengthwise direction is short.

Different nozzles can be used to make bevel cuts of different angles, where each nozzle includes a nozzle exit orifice oriented at a different angle in relation to the longitudinal axis of the nozzle body. For example, a kit of nozzle consumables can be provided that includes nozzles for making bevel cuts at <NUM>, <NUM>,<NUM> degrees, etc. The kit can also include nozzles having different numbers of guiding surfaces. Furthermore one or more templates can be included in the kit compatible with different nozzle shapes. Hence, an operator can change the nozzle as needed to achieve the desired cut angle and cut distance.

The features described with respect to <FIG> can be introduced to a plasma arc torch that includes a shield. In some examples, the shield can include at least one of the alignment surface <NUM> or the second alignment surface <NUM> described above with respect to the nozzle <NUM>. In alternative examples, the shield can include at least one of the alignment surface <NUM>, the second alignment surface <NUM>, or the third alignment surface <NUM> described above with respect to the nozzle <NUM>. The shield can further include a shield exit orifice coplanar with the nozzle exit orifice for delivering the plasma arc to impinge on a processing surface of a workpiece. The shield, upon installation into a plasma arc torch, can provide similar functions as the nozzle <NUM> or <NUM>, such as allowing an operator to maintain the torch at a perpendicular position relative to a processing surface of a workpiece while the torch delivers a plasma arc flow to the processing surface at a bevel angle and over a cutting distance.

The nozzles and/or shields of the present technology can be coated with an electrically insulating material, such as a ceramic coating. The plasma arc torches, including the nozzles and/or shields, can be constructed as handheld devices or wearable devices attached to a backpack, front-pack, and/or a shoulder strap mounted pack, for example. In addition, the nozzles and/or shields of the present technology can be used in mechanized applications, such as incorporated in X-Y cutting tables, in which case extraneous templates may not be required. For example, if the nozzle <NUM> or <NUM> is incorporated in a mechanized torch system to make bevel cuts, no complex equipment is required to manipulate to the torch and no sophisticated software is needed to perform motion control.

Featured are means for attaching one or more consumables to a plasma arc torch to achieve specific radial orientations of the consumable(s) with respect to a longitudinal axis of the torch. These consumables can include one or more asymmetric features that provide specialized cutting or gouging functions if the consumables are maintained at the desired radial orientations during torch operation. For example, one or more interfaces can be provided to radially affix the asymmetric nozzle <NUM> of <FIG> to the torch body to facilitate a flush cutting operation at a desired radial orientation of the asymmetric nozzle <NUM>. Other asymmetric features that can be enabled through specific radial orientations of consumable components include gas connections, data connections, power/electrical connections, positioning, fixturing, and/or automation features, spring mechanism for contact starting a torch, plasma processing/performance features (e.g., plasma bore, guide surface, cutting process, gouging process, washing process, severing via a plenum, bore configuration, or counter-bore configurations, etc.) and/or safety interlocking features.

<FIG> generally depicts an exemplary consumable set <NUM> of a plasma arc torch with multiple interfaces configured to couple consumables at specific radial orientations to support asymmetric torch features. <FIG> shows an exemplary plasma arc torch <NUM> comprising the elements of <FIG> for orienting asymmetric torch features. As shown in <FIG>, the consumable set includes a consumable tip <NUM>, a mounting element <NUM>, a main consumable body <NUM>, and a plasma processing interface <NUM>. The consumable set <NUM> can be coupled to a torch body <NUM> to enable torch operations, where the torch body <NUM> and the consumable set define a central longitudinal axis A extending therethrough. In some embodiments, the consumable set <NUM> is a multi-piece system with the consumable tip <NUM>, the mounting element <NUM> and the main consumable body <NUM> individually serviceable and replaceable. In some embodiments, two or more of the consumable tip <NUM>, the mounting element <NUM> and the main consumable body <NUM> form a consumable cartridge that is replaced or serviced as a unitary structure.

As shown, the consumable tip <NUM> generally defines a proximal end <NUM> and a distal end <NUM>, where the distal end <NUM> is the end along the longitudinal axis A that is maintained closest to a workpiece (not shown) during torch operation and the proximal end <NUM> is opposite of the distal end <NUM> along the longitudinal axis A. The proximal end <NUM> of the consumable tip <NUM> is adapted to be retained against the distal end <NUM> of the main consumable body <NUM> via the mounting element <NUM>. In addition, the consumable tip <NUM> can be aligned along the longitudinal axis A when mounted to the main consumable body <NUM>. In some embodiments, the consumable tip <NUM> includes one or more consumable components configured to direct a plasma arc to a workpiece to process the workpiece. Further, at least one of the consumable components of the consumable tip <NUM> includes an asymmetric feature that is asymmetrically disposed relative to the longitudinal axis A when the consumable tip <NUM> is mounted to the main consumable body <NUM>. Various embodiments of the consumable tip <NUM> are described below in relation to <FIG>, <FIG> and <FIG>.

As shown in <FIG>, the consumable tip <NUM> comprises the asymmetric nozzle <NUM> of <FIG> for flush cutting close to an internal corner of a workpiece, as described above. In this case, the nozzle exit orifice <NUM> of the nozzle <NUM> is an asymmetric feature as it is oriented at a non-zero angle relative to the longitudinal axis A when the nozzle <NUM> is connected to the torch body <NUM>. Alternatively, the consumable tip <NUM> comprises the asymmetric nozzle <NUM> of <FIG> for beveled cutting, as described above. The consumable tip <NUM> additionally includes a shield that has an asymmetric feature. As shown in <FIG>, the shield <NUM> has an asymmetric shield exit orifice <NUM> configured to deliver a plasma arc from the nozzle <NUM> to the workpiece in a flush cutting operation. In some embodiments of the consumable tip <NUM>, a locking element <NUM> is employed to radially affix at least two of the consumable components of the consumable tip <NUM> with respect to each other while permitting the asymmetric feature(s) to be radially and/or axially aligned. As shown in <FIG>, the locking element <NUM> couples the shield <NUM> to the nozzle <NUM> such that the shield exit orifice <NUM> is radially and axially aligned with the nozzle exit orifice <NUM> upon assembly of the consumable tip <NUM>. The locking element <NUM> also locks together the consumable components at the aligned position to enable the consumable tip <NUM> to move (e.g., rotate or translate) as a unitary structure. Details regarding the consumable tip <NUM> of <FIG> are provided below with reference to <FIG>. An alternative design of the consumable tip <NUM> is described below with reference to <FIG>.

In some embodiments, the mounting element <NUM> is a retaining element comprising an inner retaining cap 1002a and an outer retaining cap 1002b, as shown in <FIG>. The mounting element <NUM> includes a substantially hollow body and defines a distal end <NUM> and a proximal end <NUM>, as shown in <FIG>. The hollow body of the mounting element <NUM> is configured to house at least a portion of the main consumable body <NUM>, which can include at least one of an electrode <NUM>, a swirl ring <NUM> or a contact element <NUM> plus a resilient element <NUM> (e.g., a spring), both of which are a part of a contact starting mechanism of the plasma arc torch <NUM>. The distal end <NUM> of the mounting element <NUM> is configured to engage the consumable tip <NUM>. The proximal end <NUM> of the mounting element <NUM> is configured to engage the torch body <NUM> via the plasma processing interface <NUM>. The hollow body of the mounting element <NUM> between the proximal end <NUM> and the distal end <NUM> is configured to house at least a portion of the main consumable body <NUM>. Thus, the mounting element <NUM> can retain the consumable tip <NUM> and/or the main consumable body <NUM> against the torch body <NUM> to enable torch operations.

The mounting element <NUM> at its proximal end <NUM> can fixedly engage the plasma processing interface <NUM> by threading, for example. The fixed engagement between the mounting element <NUM> and the plasma processing interface <NUM> also locks the main consumable body <NUM> and/or the consumable tip <NUM> to the torch body <NUM> at a specific radial orientation relative to the longitudinal axis A. In some embodiments, the mounting element <NUM> first loosely engages (e.g., loosely threads into) the plasma processing interface <NUM> to permit an operator to adjust and orient (i) the main consumable body <NUM> to a desired radial orientation relative to the torch body <NUM> and/or (ii) the consumable tip <NUM> to another desired radial orientation relative to the torch body <NUM>. Then, the mounting element <NUM> can be fixedly engaged to the plasma processing interface <NUM> (e.g., by tightening the threads) to lock the main consumable body <NUM> and/or the consumable tip <NUM> in place at the adjusted radial orientations. Thus, in some embodiments, the mounting element <NUM> is rotatable about and/or translatable along the longitudinal axis A to enable its threading to the plasma processing interface <NUM>.

After loosely engaging but prior to fixedly engaging the proximal end <NUM> of the mounting element <NUM> to the torch body <NUM> via the plasma processing interface <NUM>, at least two of the mounting element <NUM>, the main consumable body <NUM> and the consumable tip <NUM> are rotatable relative to each other and to the torch body <NUM>. For example, the consumable tip <NUM> can rotate independent of the main consumable body <NUM> and/or the mounting element <NUM> such that the consumable tip <NUM> can be positioned at a specific radial orientation relative to the torch body <NUM>, thereby orienting an asymmetric feature in the consumable tip <NUM> (e.g., a nozzle bore, a drag surface, shield gas holes, etc.) at the desired radial orientation without disturbing the other components. As another example, the main consumable body <NUM> can rotate independent of the mounting element <NUM> and/or the consumable tip <NUM> prior to the fixed engagement such that the main consumable body <NUM> can be positioned at a specific radial orientation relative to the torch body <NUM> in order to support certain asymmetric electrical, fluid and data connections. Generally, such relative movement of the elements in the consumable set <NUM> prior to the fixed engagement allows independent adjustments of the elements to enable desired radial positioning of one or more asymmetric features about the longitudinal axis A prior to torch operation.

As described above, the distal end <NUM> of the mounting element <NUM> is configured to engage the proximal end <NUM> of the consumable tip <NUM>. For example, as shown in <FIG>, the proximal end <NUM> of the consumable tip <NUM> can be generally sandwiched between the outer retaining cap 1002a and the inner retaining cap 1002b. Prior to the mounting element <NUM> being fixedly engaged to the plasma processing interface <NUM> at the proximal end <NUM> (i.e., during loose engagement), the mounting element <NUM> can longitudinally constrain (i.e., axially secure) the consumable tip <NUM> relative to the main consumable body <NUM> while permitting independent rotation of the consumable tip <NUM> relative to the mounting element <NUM>. Such rotatable engagement and axial securement can be accomplished by one of crimping, snap fitting, frictional fitting, threading, grooves, etc..

In some embodiments, the rotatable engagement and axial securement between the mounting element <NUM> and the consumable tip <NUM> occurs at (i) the interface <NUM> between an outer surface of the shield <NUM> of the consumable tip <NUM> and an inner surface of the outer retaining cap 1002a, and/or (ii) the interface <NUM> between a proximal surface of the nozzle <NUM> of the consumable tip <NUM> and a distal surface of the inner retaining cap 1002b. For example, the shield <NUM> can include an engagement feature, such as a groove or step, circumferentially disposed on an outer surface that allows a distal tip of the outer retaining cap 1002a to frictionally fit into the groove or step. Similarly, the nozzle <NUM> can include an engagement feature, such as a groove or step, circumferentially disposed at a proximal surface that allows a distal tip of the inner retaining cap 1002b to abut against the groove or step. In some embodiments, to attach the consumable tip <NUM> to the mounting element <NUM>, the consumable tip <NUM> is pushed into the distal opening of the mounting element <NUM> (i.e., the distal opening defined by the outer retaining cap 1002a) until the proximal surface of the nozzle <NUM> of the consumable tip <NUM> physically contacts the distal surface of the inner retaining cap 1002b to form the interface <NUM>, at which position further axial advancement of the consumable tip <NUM> within the mounting element <NUM> is hindered. Also, at this position, the distal end of the outer retaining cap 1002a rotatably engages the proximal end of the shield <NUM> of the consumable tip to form the interface <NUM>.

In some embodiments, the proximal end <NUM> of the mounting element <NUM>, such as the proximal end of the outer retaining cap 1002a, can fixedly engage the plasma processing interface <NUM> that is coupled to the torch body <NUM>. Such fixed engagement can be achieved through full threading of the mounting element <NUM> relative to the torch body <NUM>, for example. This securement causes the mounting element <NUM> to impart a frictional force on the consumable tip <NUM> via at least one of the interface <NUM> or interface <NUM> at the distal end <NUM> of the mounting element <NUM>, thereby causing the mounting element <NUM> to clamp down on the consumable tip <NUM> to fixedly engage the consumable tip <NUM> at a particular radial orientation about the longitudinal axis A. The fixed engagement of the mounting element <NUM> with the consumable tip <NUM> thus locks an asymmetric feature (e.g., the nozzle exit orifice <NUM> and/or the shield exit orifice <NUM>) of the consumable tip <NUM> at a specific radial orientation such that a first alignment surface <NUM> and/or a second alignment surface <NUM> disposed on an external surface of the shield <NUM> can fit into a corner of a workpiece to perform flush cutting. The alignment surface <NUM>, <NUM> can be substantially similar to the alignment surfaces <NUM>, <NUM>, respectively, of the asymmetric nozzle <NUM> of <FIG>.

As described above, during the loose engagement between the mounting element <NUM> and the plasma processing interface <NUM>, an operator can adjust the radial orientation of the consumable tip <NUM> about the longitudinal axis A such that it is locked at a desired radial orientation after fixed engagement between the mounting element <NUM> and the plasma processing interface <NUM>. In some embodiments, the exterior surfaces of the consumable components in the consumable tip <NUM>(e.g., the shield <NUM> at the interface <NUM> and/or the nozzle <NUM> at the interface <NUM>) are relatively smooth, such that an operator can freely rotate the consumable tip <NUM> to achieve any desired radial orientation prior to the fixed engagement. In some embodiments, the consumable components of the consumable tip <NUM> have a set of predetermined orientations (e.g., at <NUM> degree increments), which may be clocked into by the mounting element <NUM> prior to the fixed engagement. These fixed positions can be implemented by a variety of mechanical means such as detents and/or magnets on an exterior surface of the consumable tip <NUM> and complementary features on a surface of the mounting element <NUM> (or vice versa). In one embodiment where detents are used, the detents allow the consumable tip <NUM> to settle into a predetermined specific radial orientation (e.g., <NUM> degrees) relative to a torch handle. In some embodiments, the mechanical means (e.g., detents) can be located relative to a threading arrangement between the mounting element <NUM> and the consumable tip <NUM> to achieve a substantially accurate/predetermined radial relationship between the consumable tip <NUM> and the mounting element <NUM>.

In some embodiments, the mounting element <NUM> is fixedly attached to the consumable body <NUM>, such that the consumable body <NUM> rotates and translates with the mounting element <NUM> during both loose engagement and fixed engagement as the mounting element <NUM> is threaded to the plasma processing interface <NUM>. In this case, the consumable body <NUM> can be substantially symmetrical about the longitudinal axis A so that the consumable body <NUM> does not need to be positioned and clocked at a specific radial orientation relative to the torch body <NUM>. For example, the consumable body <NUM> of <FIG>, which includes the contact element <NUM>, the resilient element <NUM>, the electrode <NUM>, and the swirl ring <NUM>, is substantially symmetrical about the longitudinal axis A and does not need to be oriented at any particular radial position relative to the torch body <NUM> to support torch operations.

In some embodiments, the consumable body <NUM> is rotatable independent of the mounting element <NUM> and/or the consumable tip <NUM> during the loose engagement between the mounting element <NUM> and the plasma processing interface <NUM>. Therefore, an operator can adjust the radial orientation of the consumable body <NUM> about the longitudinal axis A such that it is positioned at a desired radial orientation with respect to the plasma processing interface <NUM> prior to being locked into place by the fixed engagement between the mounting element <NUM> and the plasma processing interface <NUM>. Specifically, the fixed engagement between the mounting element <NUM> and the plasma processing interface <NUM> can impart a frictional force between the mounting element <NUM> and the consumable body <NUM> to lock the consumable body <NUM> in place both radially and axially relative to the plasma processing interface <NUM>. In this case, the consumable body <NUM> may have one or more asymmetric features with respect to the longitudinal axis A that require the specific radial orientation in order to achieve a desired alignment with the processing interface <NUM>. In turn, the plasma processing interface <NUM> can define an asymmetric geometry configured to receive and mate with the consumable body <NUM> at the specific radial orientation. For example, clocking of the plasma processing interface <NUM> with the proximal end <NUM> of the consumable body <NUM> at a predefined radial orientation can enable alignment of various data, electrical, liquid coolant, and gas channels between the torch body <NUM> and the consumable body <NUM> via the plasma processing interface <NUM>. In some embodiments, the plasma processing interface <NUM> is fixedly attached to the torch body <NUM>, such as integrally formed with the torch body <NUM>.

<FIG> shows a sectional view of an exemplary consumable cartridge <NUM> with asymmetric features that require clocked radial orientation relative to the plasma processing interface <NUM> that is coupled to the torch body <NUM> of <FIG>. The consumable cartridge <NUM> essentially encapsulates the mounting element <NUM>, the main consumable body <NUM> and the consumable tip <NUM> in one unitary structure. The consumable cartridge <NUM> can be substantially the same as the cartridge <NUM> described in <CIT>, which is assigned to Hypertherm, Inc. of Hanover, N. The cartridge <NUM> is attachable to the torch body <NUM> via the plasma processing interface <NUM>. The cartridge <NUM> generally defines a proximal end <NUM> and a distal end <NUM> along the central longitudinal axis A of the torch body <NUM>. As shown, the cartridge <NUM> includes a cartridge frame <NUM> coupled to one or more of an electrode <NUM>, a nozzle <NUM>, a swirl ring <NUM>, and a shield <NUM> disposed concentrically about the central longitudinal axis A. Even though the nozzle <NUM> and the shield <NUM> of <FIG> do not include an asymmetric feature, in other examples, at least one of the nozzle <NUM> or the shield <NUM> includes an asymmetric feature, such as the asymmetric nozzle exit orifice of <FIG> and/or the asymmetric shield exit orifice of <FIG>. In these asymmetric examples, as in the embodiments of <FIG> described above, these asymmetric features at the distal end <NUM> of the consumable cartridge <NUM> may be clocked as described above to radially orient the consumable tip <NUM> relative to the longitudinal axis A as desired regardless of the clocking requirement of the proximal end <NUM> of consumable cartridge <NUM>.

The cartridge frame <NUM> is adapted to physically interface with the plasma processing interface <NUM>, thereby connecting the cartridge <NUM> to the torch body <NUM>. <FIG> shows a view of the proximal end <NUM> of the cartridge frame <NUM> of the cartridge <NUM> of <FIG>. The proximal end <NUM> of the cartridge frame <NUM> can include a clocking feature (e.g., a pin cavity) <NUM> that can interact with a corresponding clocking feature of the plasm processing interface <NUM> to connect the torch body <NUM> to the cartridge <NUM>. Such an interface allows alignment of various electrical, liquid coolant, and gas channels between the torch body <NUM> and the cartridge <NUM>, thereby maintaining one or more predefined electrical, liquid coolant and gas flow paths across the torch system. <FIG> shows an exemplary design of the plasma processing interface <NUM> that includes various electrical, gas and liquid openings corresponding to the openings at the proximal end <NUM> of the cartridge frame <NUM> of <FIG>, as well as a clocking feature <NUM> (e.g., a pin) adapted to interact with the clocking feature <NUM> of the proximal end <NUM> of the cartridge frame <NUM> to align the two components at a predetermined radial orientation.

With respect to the continuity of gas flows between the torch body <NUM> and the cartridge <NUM>, in the predetermined radial orientation, a shield gas opening 1426b on the plasma processing interface <NUM> is aligned with a shield gas opening 1364a at the proximal end <NUM> of the cartridge frame <NUM> to fluidly connect a shield gas channel segment (not shown) of the torch body <NUM> with a shield gas channel (not shown) of the cartridge frame <NUM> to deliver a shield gas flow from the torch body <NUM> to the cartridge <NUM>. In the same predetermined radial orientation, a plasma gas opening 1421c on the plasma processing interface <NUM> is aligned with a plasma gas proximal opening 1312a at the proximal end <NUM> of the cartridge frame <NUM> to fluidly connect a plasma gas channel (not shown) of the torch body <NUM> with a plasma gas channel (not shown) of the cartridge frame <NUM> to deliver a plasma gas from the torch body <NUM> to the cartridge <NUM>.

With respect to the continuity of coolant flow between the torch body <NUM> and the cartridge <NUM>, upon clocking of the plasma processing interface <NUM> with the cartridge frame <NUM> in the predetermined radial orientation, a first liquid coolant channel opening 1460a on the plasma processing interface <NUM> is aligned with a first coolant channel opening 1362a at the proximal end <NUM> of the cartridge frame <NUM> to fluidly connect a first liquid coolant channel (not shown) of the torch body <NUM> with a first liquid coolant channel (not shown) of the cartridge frame <NUM>, thereby allow a liquid coolant to be delivered from the torch body <NUM> to the cartridge <NUM>. In the same predetermined radial orientation, a second liquid coolant channel opening 1460b on the plasma processing interface <NUM> is aligned with a second coolant channel opening 1368a at the proximal end <NUM> of the cartridge frame <NUM> to fluidly connect a second coolant channel (not shown) of the torch body <NUM> with a second coolant channel (not shown) of the cartridge frame <NUM> to return a liquid coolant flow from the cartridge <NUM> to the torch body <NUM>. In the same predetermined radial orientation, a third liquid coolant channel opening 1460c on the plasma processing interface <NUM> is aligned with a third coolant channel opening 1378a at the proximal end <NUM> of the cartridge frame <NUM> to fluidly connect athird coolant channel (not shown) of the torch body <NUM> with a third coolant channel (not shown) of the cartridge frame <NUM> to again deliver a liquid coolant flow from the torch body <NUM> to the cartridge <NUM>. In the same predetermined radial orientation, a fourth liquid coolant channel opening 1460d on the plasma processing interface <NUM> is aligned with a fourth coolant channel opening 1382a of the cartridge frame <NUM> to fluidly connect a fourth coolant channel (not shown) of the torch body <NUM> with a fourth coolant channel (not shown) of the cartridge frame <NUM> to again return a liquid coolant flow from the cartridge <NUM> to the torch body <NUM>.

With respect to data communication between the torch body <NUM> and the cartridge <NUM>, in the predetermined radial orientation enabled by the clocking features <NUM>, <NUM>, a reader device, such as an RFID reader device, of the torch body <NUM> (not shown) is rotationally aligned with a signal device <NUM>, such as an RFID tag, of the cartridge <NUM> (shown in <FIG>). For example, an antenna coil embedded in the torch body <NUM> can map to an area <NUM> at the plasma processing interface <NUM> with a center <NUM> that substantially aligns with a center <NUM> of an area <NUM> at the proximal end <NUM> of the cartridge frame <NUM>, which maps to the signal device <NUM> embedded in the cartridge <NUM>. Such radial alignment between the centers <NUM>, <NUM> reduces communication interference between the reader device and the signal device <NUM> to facilitate data communication across the torch system.

With respect to the continuity of electrical connections between the torch body <NUM> and the cartridge <NUM>, upon interfacing the plasma processing interface <NUM> with the cartridge frame <NUM>, a central opening 1332b of the plasma processing interface <NUM> is adapted to align with a central opening 1320a at the proximal end <NUM> of the cartridge frame <NUM> to connect a main channel (not shown) of the torch body <NUM> with a main channel (not shown) of the cartridge frame <NUM>. A conductive coolant tube <NUM> is adapted to be inserted into the connected main channels across the torch body <NUM> and the cartridge frame <NUM>. A pilot arc current and/or a transferred arc current from a power supply (not shown) may be routed from the torch body <NUM>, through the coolant tube <NUM>, and to the electrode <NUM> of the cartridge <NUM>.

<FIG> are merely illustrative of a particular arrangement of gas, fluid, electrical, and data communication connections across the plasma processing interface <NUM> and the proximal end <NUM> of the cartridge frame <NUM>. Other layouts of one or more of these connections are also within the scope of the present invention. Generally, one or more of these connections can be arranged in a variety of geometries and locations on the plasma processing interface <NUM> and correspondingly on the proximal end <NUM> of the cartridge frame <NUM> to facilitate electrical, data, gas and liquid circulation across a plasma arc torch.

The plasma processing interface <NUM> of the torch body <NUM> may include an ejector feature that mechanically ejects the consumable body <NUM> (or the cartridge <NUM>) if the consumable body <NUM> (or the cartridge <NUM>) is not properly positioned or aligned with the torch body <NUM>.

As described above with reference to <FIG>, the consumable tip <NUM> of the consumable set <NUM> of <FIG> generally includes one or more consumable components, with at least one of the consumable components having an asymmetric feature. In some embodiments, an asymmetric feature can define an axis that is oriented at a non-zero angle relative to the central longitudinal axis A (when the consumable tip <NUM> is connected to the main consumable body <NUM>). In some embodiments, an asymmetric feature defines an axis that is offset from the central longitudinal axis A. In some embodiments, an asymmetric feature defines an asymmetric cross section about the central longitudinal axis A.

<FIG> shows an exemplary design of the consumable tip <NUM> of <FIG> that is implemented in the plasma arc torch <NUM> of <FIG>. As shown, the consumable tip <NUM> includes the nozzle <NUM>, which is described above in detail with respect to <FIG> for performing flush cutting operations. The nozzle <NUM> includes an asymmetric nozzle exit orifice <NUM> (shown in <FIG>) with an axis that is oriented at a non-zero angle (e.g., an acute angle) relative to the central longitudinal axis A. The consumable tip <NUM> also includes the shield <NUM> having an asymmetric shield exit orifice <NUM> (shown in <FIG>) with an axis that is oriented relative to the central longitudinal axis A at about the same non-zero angle as the nozzle exit orifice <NUM>. The consumable tip <NUM> further includes the locking element <NUM> that is adapted to be positioned between the nozzle <NUM> and the shield <NUM> to fixedly couple the two consumable components together while radially and/or axially aligning the asymmetric nozzle exit orifice <NUM> with the asymmetric shield exit orifice <NUM>. To achieve such alignment, the consumable components of the consumable tip <NUM> (e.g., the nozzle <NUM> and the shield <NUM>) as well as the locking element <NUM> can include complementary features configured to inter-fit with one another only when the asymmetric features of the consumable components are radially and/or axially aligned. For example, as shown in <FIG>, the complementary features comprise a flat surface <NUM> disposed on a corresponding circumferential section of each of the consumable components and the locking element <NUM>. To properly assemble the nozzle <NUM>, the shield <NUM> and the locking element <NUM>, the flat surfaces <NUM> of these components need to be aligned, which also radially and axially align the nozzle exit orifice <NUM> with the shield exit orifice <NUM>. The locking element <NUM> is further configured to lock the consumable components at the aligned position (e.g., via interference fit) such that the consumable tip <NUM> moves (e.g., rotates or translates) as a unitary component.

In another exemplary design of the consumable tip <NUM> of <FIG>, the consumable tip <NUM> includes an asymmetric nozzle that can be used to cut a workpiece or gouge a workpiece depending on the radial orientation of the asymmetric nozzle bore relative to the longitudinal axis A. <FIG> show a top view and a cut-away view, respectively, of an exemplary asymmetric nozzle <NUM> that can be used as the consumable tip <NUM> of <FIG> to perform either a cutting or gouging operation.

As shown, the nozzle <NUM> has a nozzle exit orifice <NUM> with an asymmetrically-shaped (e.g., elliptical) cross section <NUM> about the longitudinal axis A. To perform a cutting operation, the major axis of the elliptical cross section <NUM> of the nozzle exit orifice <NUM> is in the direction of the cut (e.g., direction of travel of the torch) such that a prolonged arc is produced for the cutting operation. To perform a gouging operation, the major axis of the elliptical cross section <NUM> of the nozzle exit orifice <NUM> is perpendicular to the direction of the gouge such that a dispersed arc is produced for the gouging operation. The consumable tip <NUM> may also include a shield that does not have an asymmetric feature (i.e., is substantially symmetrically about the longitudinal axis A). The consumable tip <NUM> may be assembled such that asymmetric nozzle <NUM> and the symmetrical shield are locked together to form a unitary structure. Prior to torch operation, an operator can rotate the consumable tip <NUM> to a particular radial orientation about the longitudinal axis A that is independent of the positions of the other elements the consumable set <NUM> and lock that particular radial orientation of the consumable tip <NUM> in place. This allows the operator to control the orientation of the elliptical cross section <NUM> of the nozzle exit orifice <NUM> relative to the torch based on whether the operator wants to perform a cutting or gouging operation. A consumable tip design incorporating the nozzle <NUM> can be implemented in the plasma arc torch <NUM> of <FIG> in place of the flush-cutting consumable tip. This consumable tip design can also be implemented in the cartridge <NUM> of <FIG> in place of the substantially symmetrical consumable tip.

The asymmetric nozzle <NUM> may be used in the consumable tip <NUM> of <FIG> to perform a gouging operation by delivering a diffused stream of plasma arc with a non-circular cross-sectional shape to a workpiece. The nozzle <NUM> is configured to achieve a wide gouge profile in a workpiece without multiple passes by the torch <NUM> over the workpiece and/or without oscillation. As shown, the nozzle <NUM> includes a nozzle body defining a central longitudinal axis A extending between a distal end <NUM> (i.e., the end closest to the workpiece during torch operation) and a proximal end <NUM> (i.e., the end opposite of the distal end <NUM>). The nozzle exit orifice <NUM>, located at the distal end <NUM> of the nozzle body, defines at least a bore <NUM> for conducting the plasma arc.

In addition, a counter bore feature <NUM> is disposed relative to the distal end <NUM> of the nozzle body and fluidly connected to the bore <NUM> along the longitudinal axis A, such as located distally to the bore <NUM>. At least one of the bore <NUM> or the counter bore feature <NUM> has a non-circular cross-sectional shape in the plane (defined by the B and B' axes) perpendicular to the longitudinal axis A. The non-circular shape can have different configurations, as described below. The cross-sectional shape of the counter bore feature <NUM>, which represents a flow area, also has a larger cross-sectional area than that of the bore <NUM> to reduce the plasma arc's energy, density and velocity during a gouge operation.

In the example illustrated in <FIG>, both the bore <NUM> and the counter bore feature <NUM> are disposed in the nozzle <NUM> and both are defined by the nozzle exit orifice <NUM>, such that they are substantially aligned along the longitudinal axis A in the nozzle exit orifice <NUM>. In other examples (not illustrated), the counter bore feature <NUM> is located in other components of the consumable tip <NUM>. For example, the counter bore feature <NUM> can be disposed on a shield connected to the nozzle <NUM>, where the counter bore feature <NUM> is defined by a shield exit orifice. Upon connection of the shield to the nozzle <NUM>, the bore <NUM> and the counter bore feature <NUM> are adapted to substantially align along the longitudinal axis A.

In the examples illustrated in <FIG>, the counter bore feature <NUM> is a counter bore. In other examples, the counter bore feature <NUM> is a counter sink. A counter bore is substantially rectangular in shape in the plane defined by the longitudinal axis A and the transversal axis B, whereas a counter sink is substantially conical in shape in the same plane. Many other counter bore feature shapes are also within the scope of the invention, and many can have dimensions along the B and B' axes that are different.

As described above, at least one of the bore <NUM> or the counter bore feature <NUM> has a non-circular cross-sectional shape in the plane perpendicular to the longitudinal axis A, where the plane is defined by a first transversal axis B and a second transversal axis B' perpendicular to each other. The non-circular cross-sectional shape can have a first length along the first transversal axis B different than a second length along the second transversal axis B (e.g., the first length greater than or less than the second length). For example, the non-circular cross-section shape can be one of an ellipse, a trapezoid, a triangle, tri-lobed, a rectangle or a slot (i.e., a hybrid rectangle-ellipse, such as a rectangle with rounded corners). These different shapes of the bore <NUM> and/or the counter bore feature <NUM> provide the operator the freedom to create variations in the gouge profiles in the workpiece.

The cross-sectional shape of the bore <NUM> may be circular while the cross-sectional shape of the counter bore feature <NUM> is non-circular. The cross-sectional shape of the bore <NUM> may be non-circular while the cross-sectional shape of the counter bore feature <NUM> is circular. The cross-sectional shapes of the bore <NUM> and the counter bore feature <NUM> may both be non circular and these non-circular shapes can be the same or different from each other. For example, as illustrated in <FIG>, the cross-sectional shape of the bore <NUM> is elliptical while the cross-sectional shape of the counter bore feature <NUM> has a slot shape (i.e., rectangular with rounded corners). The slotted cross-sectional shape of the counter bore feature <NUM> has a larger area than that of the elliptical cross-sectional shape of the bore <NUM>. The cross-sectional shapes of both the bore <NUM> and the counter bore feature <NUM> may be elliptical.

In contrast to having the typical circular cross-sectional shape for both the bore <NUM> and the counter bore feature <NUM>, the non-circular cross-sectional shape for at least one of the bore <NUM> or the counter bore feature <NUM> described in the present invention allows the plasma arc to achieve a non-circular cross-sectional shape (e.g., elliptical) when delivered to the workpiece. For example, the plasma arc can become diffused through an expansion in the first transversal axis B or the second transversal axis B', thus reducing the plasma arc's ability to melt the metallic workpiece fast enough to keep up with the linear speed of the operation, thereby producing a gouge in the workpiece after a single pass of the torch relative to the workpiece rather than a cut. The non-circular cross-sectional shape of the diffused plasma arc may be such that is has a first length along the first transversal axis that is different from a second length along the second transversal axis. Further, from a single pass of the torch relative to the workpiece and/or without oscillating torch motion, a traditional torch (i.e., having the typical circular cross-sectional shape for both the bore <NUM> and the counter bore feature <NUM>) can only produce a relatively symmetric gouge profile in the workpiece with a width to depth ratio of at most <NUM> to <NUM>. By expanding the cross section of at least one of the bore <NUM> or the counter bore feature <NUM> along the transversal axis B or B', a proportional growth of the width and reduction of the depth of the gouge profile is achieved. The resulting gouge profile in the workpiece may be non-symmetric and may have a width to depth ratio of greater than <NUM> to <NUM>.

Because the bore <NUM> and/or the counter bore feature <NUM> are non-circular in the cross section, its locational position can be clocked (i.e., positioned at a particular radial orientation in the B-B' plane relative to the longitudinal axis A). Thus, the directionality of the resulting plasma arc relative to the torch or torch motion can be adjusted to provide directional dispersal of the plasma arc onto the workpiece during a gouge operation. For example, if the plasma arc has an elliptical cross section, the bore <NUM> and/or the counter bore feature <NUM> can be adjusted such that the major axis of the elliptical cross-sectional shape of the plasma arc is oriented substantially perpendicular to the direction of the gouge path in the workpiece. Thus, if the cross section of at least one of the bore <NUM> or the counter bore feature <NUM> is elliptical, the major axis of the elliptical cross-sectional shape of the bore <NUM> or the counter bore feature <NUM> is also oriented substantially perpendicular to the direction of the gouge path in the workpiece. This directional orientation of the bore <NUM> and/or the counter bore feature <NUM> allows the resulting gouge profile in the workpiece to obtain a width greater than depth (e.g., a width to depth ratio of greater than <NUM> to <NUM>) after a single pass by the torch over the workpiece at a normal process speed and without torch oscillation. If the cross section of at least one of the bore <NUM> or the counter bore feature <NUM> is elliptical and the major axis of the elliptical cross-sectional shape of the bore <NUM> or the counter bore feature <NUM> is oriented substantially perpendicular to the workpiece in the direction of motion of the torch tip, this may result in a gouging profile with a width to depth ratios of about <NUM>:<NUM> or lower for higher metal removal rates.

If the bore <NUM> and the counter bore feature <NUM> are both disposed on the nozzle <NUM>, the nozzle may be clocked relative to the torch handle to achieve the directional dispersal in the resulting plasma arc. If the bore <NUM> is disposed on the nozzle <NUM> and the counter bore feature <NUM> is disposed on a shield, both the nozzle and the shield may be clocked to achieve the directional dispersal in the resulting plasma arc. To achieve clocking for the bore <NUM> and/or the counter bore feature <NUM>, prior to a gouge operation, an operator can first align the nozzle <NUM> and the shield using the approach described above with reference to <FIG> to assemble the consumable tip <NUM> such that the nozzle <NUM> and shield are at a desired orientation relative to each other. For example, if the bore <NUM> is disposed on the nozzle <NUM> and the counter bore feature <NUM> is disposed on the shield, to achieve the cross-sectional configuration of <FIG>, the elliptical shaped cross section of the bore <NUM> of the nozzle <NUM> is aligned with the rectangular shaped cross section of the counter bore feature <NUM> of the shield in such a manner that the centers of both shapes are aligned, the axes associated with the shorter lengths of both shapes are aligned, and the axes associated with the longer lengths of both shapes are aligned. Then, the operator can rotate the assembled consumable tip <NUM> to a particular radial orientation about the longitudinal axis A and lock that particular radial orientation of the consumable tip <NUM> in place. The consumable tip design incorporating the bore <NUM> and the counter bore feature <NUM> as described above can be implemented in the plasma arc torch <NUM> of <FIG> in place of the flush-cutting consumable tip. This consumable tip design can also be implemented in the cartridge <NUM> of <FIG> in place of the substantially symmetrical consumable tip. The bore <NUM> and the counter bore feature <NUM> may both disposed in the nozzle <NUM>, while a second bore feature (not shown), with a circular or non-circular cross section, is disposed in the shield. The nozzle <NUM> and shield can be connected to each other using the approach described above with respect to <FIG>.

The nozzle <NUM> may further define a set of gas passageways disposed about the bore <NUM>. Each gas passageway has a port <NUM> arranged about the distal end <NUM> of the nozzle <NUM> in a non-circular manner as shown in <FIG>. For example, the arrangement of the ports can be such that one or more ports are missing around a flat surface <NUM> disposed on a circumferential section of the nozzle <NUM>. The flat surface <NUM> of the nozzle <NUM> is adapted to correspond to the flat surface <NUM> of the locking element <NUM> and a flat surface (not shown) of a shield. As described above with respect to <FIG>, when assembling the nozzle <NUM>, the shield and the locking element <NUM> to form a consumable tip, these flat surfaces of the consumable components are aligned, which also radially and axially align the bore <NUM> of the nozzle exit orifice <NUM> with counter bore feature <NUM> of the shield exit orifice. The locking element <NUM> locks the consumable components at the aligned position (e.g., via interference fit) such that the consumable tip <NUM> moves (e.g., rotates or translates) as a unitary component. The flat surface <NUM> may indicate the direction the torch <NUM> needs to be dragged during a gouging operation.

Table <NUM> below shows the test results of nozzles with various configurations illustrated in <FIG>. To obtain the test results, these nozzles were operated at <NUM> amps, a torch angle of <NUM> degrees, a speed of <NUM> impressions per minute (ipm) and a standoff of about <NUM> ( <NUM> inches). Specifically, the "Rev <NUM>" row of Table <NUM> shows characteristics of a gouge profile obtained using a traditional nozzle <NUM> of <FIG>, where the cross-sectional shapes of the bore 1902a and the counter bore feature 1902b of the nozzle <NUM> are both circular. The "Rev <NUM> (V)" and "Rev <NUM> (H)" rows of Table <NUM> show characteristics of a gouge profile obtained using the nozzle <NUM> of <FIG>, where the cross-sectional shape of the bore 1904a is circular and the cross-sectional shape of the counter bore feature 1904b is elliptical. Specifically, the designation "V" is used when the narrower dimension <NUM> (i.e., the minor axis) of the elliptical counter bore feature 1904b is oriented substantially parallel to the direction of the gouge by the torch, thus yielding a narrower and deeper gouge. The designation "H" is used when the wider dimension <NUM> (i.e., the major axis) of the elliptical counter bore feature 1904b is oriented substantially parallel to the direction of torch travel, thus yielding a wider and shallower gouge. The "Rev <NUM> (V)" and "Rev <NUM> (H)" rows of Table <NUM> show characteristics of a gouge profile obtained using the nozzle <NUM> of <FIG>, where the cross-sectional shapes of the bore 1906a and the counter bore feature 1906b are both elliptical. Similarly, the designation "V" is used when the narrower dimension <NUM> of both the elliptical bore 1906a and counter bore feature 1906b is oriented substantially parallel to the direction of the gouge by the torch, and the designation "H" is used when the wider dimension <NUM> of both the elliptical bore 1906a and counter bore feature 1906b is oriented substantially parallel to the direction of torch travel. The "stock PMX <NUM>" row of Table <NUM> shows characteristics of a gouge profile obtained using the existing Hyperterm™ PMX <NUM> nozzle, where the cross-sectional shapes of the bore and the counter bore feature of the nozzle are also both circular. As shown, the gouge profile created using the "Rev <NUM> (H)" nozzle, which corresponds to the nozzle shown in <FIG>, has the best width-to-depth ratio of greater than <NUM> (i.e., <NUM>) and the lowest volume (of workpiece material removed) of <NUM><NUM>. Generally, the less the workpiece material removed indicates more control by the torch in a single pass and the greater the dispersion of the plasma arc. The gouge profile created using the "Rev <NUM> (H)" nozzle, which corresponds to the nozzle shown in <FIG>, has the second best width-to-depth ratio of <NUM> and the second lowest volume of <NUM>. Thus, these tests results indicate that a non-circular cross-sectional shape for at least one of the bore or the counter bore feature in the torch tip of a plasma arc torch produces a superior gouge profile with an optimized width-to-depth ratio.

<FIG> shows an isometric view of the plasma arc torch <NUM> of <FIG> fully assembled. As described above, the consumable tip <NUM> comprises the nozzle <NUM> coupled to and aligned with the shield <NUM> such that the nozzle exit orifice <NUM> and the shield exit orifice <NUM> are radially affixed to each other. The consumable tip <NUM> forms a unitary structure, where the nozzle <NUM> and the shield <NUM> rotate together as a single unit. The consumable tip <NUM> is independently rotatable about the longitudinal axis A prior to the fixed engagement of the mounting element <NUM> to the torch body <NUM> via the plasma processing interface <NUM>. This allows an operator to orient the consumable tip <NUM> such that its asymmetric feature (e.g., the nozzle exit orifice <NUM> and/or the shield exit orifice <NUM>) is at a specific radial orientation about the longitudinal axis A, thereby permitting the first alignment surface <NUM> and/or the second alignment surface <NUM> of the shield <NUM> to also rotate to a position such that they can fit into a corner of a workpiece to perform flush cutting. In some embodiments, prior to the fixed engagement, the main consumable body <NUM> is also independently rotatable about the longitudinal axis A (as indicated by the arrow) such that it can be clocked into a predetermined radial orientation with the plasma processing interface <NUM> in order to maintain certain electrical, data, gas and/or liquid connections between the torch body <NUM> and the consumable set <NUM>. Fixed engagement between the mounting element <NUM> and the torch body <NUM> via the plasma processing interface <NUM> allows the various radial orientations of the elements in the consumable set <NUM> to be locked into place during torch operation.

<FIG> shows an exemplary process <NUM> for assembling the consumable set <NUM> of <FIG> to a torch body. As described above, the consumable set <NUM> can be encapsulated in a cartridge or comprise multiple separate pieces. The process <NUM> includes loosely engaging the proximal end <NUM> of the mounting element <NUM> to the plasma processing interface <NUM> by, for example, threading (step <NUM>). For example, the loose engagement can be achieved by partial threading (e.g., threading <NUM>% from being fully threaded), so that the mounting element <NUM> is only loosely connected to the plasma processing interface <NUM>. After the loose engagement, the distal end <NUM> of the mounting element <NUM> axially secures the consumable tip <NUM> while permitting independent rotation of the consumable tip <NUM> about the longitudinal axis A relative to the mounting element <NUM>. The consumable tip <NUM> includes multiple consumable components, where at least one consumable component has an asymmetric feature that is asymmetrically disposed in the consumable tip <NUM> relative to the longitudinal axis A. For example, the consumable tip <NUM> can be implemented (i) as the design of <FIG> for flush cutting or (ii) include the asymmetric nozzle <NUM> of <FIG> for selectively performing a cutting or gouging operation.

In some embodiments, if the consumable set <NUM> is a cartridge, the mounting element <NUM>, the main consumable body <NUM> and/or the consumable tip <NUM> are already assembled together prior to the loose engagement, but these elements are rotatably coupled relative to each other such that they can rotate independently about the longitudinal axis A. In some embodiments, if the consumable set <NUM> comprises multiple separate elements, the process <NUM> also includes, prior to the loose engagement, assembling the consumable tip <NUM> by fixedly locking the multiple consumable components of the consumable tip <NUM> together using, for example, the locking element <NUM>. The locking of the consumable components in the consumable tip <NUM> is adapted to axially and radially align the one or more asymmetric features in the consumable tip <NUM> while enabling the consumable tip <NUM> to function as a unitary structure. In addition, prior to the loose engagement, the consumable body <NUM> can be disposed in the hollow body of the mounting element <NUM> and the consumable tip <NUM> can be rotatably engaged to the distal end <NUM> of the mounting element <NUM>.

After the loose engagement between the proximal end <NUM> of the mounting element <NUM> and the torch body <NUM> via the plasma processing interface <NUM>, the consumable tip <NUM> can be oriented/adjusted relative to the mounting element <NUM> about the longitudinal axis A to attain a specific radial orientation of the asymmetric feature of the consumable tip <NUM> with respect to the longitudinal axis A (step <NUM>). For example, in the case of flush cutting, the aligned nozzle exit orifice <NUM> and shield exit orifice <NUM> can be positioned at a specific radial orientation about the longitudinal axis A, which in turn rotates the first alignment surface <NUM> and/or the second alignment surface <NUM> of the shield <NUM> to a position so that they can fit into a corner of a workpiece to perform flush cutting. In the case of selective gouging or cutting with the nozzle <NUM> incorporated in the consumable tip <NUM>, the consumable tip <NUM> can be rotated to a desired radial orientation such that the major axis of the elliptical cross section <NUM> of the nozzle exit orifice <NUM> is either parallel or perpendicular to the direction of the torch operation, depending on whether cutting or gouging is desired by the operator.

After the consumable tip <NUM> is positioned at a desired radial orientation, the proximal end <NUM> of the mounting element <NUM> is fixedly engaged to the plasma processing interface <NUM> by, for example, tightening the remaining <NUM>% of the threads (step <NUM>). The fixed engagement imparts a frictional force between the mounting element <NUM> and the consumable tip <NUM> to both axially and radially secure the consumable tip <NUM> to the torch body <NUM>, such that the asymmetric feature of the torch tip is <NUM> is locked at the specific radial orientation (set from step <NUM>).

Claim 1:
A consumable tip (<NUM>) for a plasma arc torch configured to direct a plasma arc to a workpiece to process a processing surface of the workpiece, the consumable tip comprising:
a nozzle (<NUM>) including a nozzle body (<NUM>) defining a central longitudinal axis (A) extending therethrough and a nozzle exit orifice (<NUM>) disposed in the nozzle body (<NUM>), defining an exit orifice axis (B) extending longitudinally along the length of the nozzle exit orifice (<NUM>) from an interior opening (225b) of the nozzle body to an exterior opening (225a) of the nozzle body; the nozzle exit orifice is rotationally asymmetrically disposed in the nozzle body relative to the central longitudinal axis (A);
a shield (<NUM>) including a shield body and a shield exit orifice (<NUM>) asymmetrically disposed in the shield body relative to the central longitudinal axis (A); and
a locking element (<NUM>) positioned between the nozzle and the shield for fixedly couple the nozzle and the shield with respect to each other to maintain radial and axial alignment between the shield exit orifice and the nozzle exit orifice.