Patent ID: 7659488

Claim:
A composite electrode for use in a plasma arc torch comprising: a body defining a bore and a cooling area which receives a coolant, the body comprising a forward portion, an aft portion, and a forged weld joint; the forward portion of the body comprising a first material with a heat transfer property, the forward portion including a first mating surface; the aft portion of the body comprising a second material different from the first material, the heat transfer property of the second material is different than the heat transfer property of the first material, the aft portion including a second mating surface; and the forged weld joint formed between the forward and aft portions along the first and second mating surfaces without introduction of an additional material to provide direct metallurgical coupling between the first material and the second material along the forged weld joint, the forged weld joint being leak-proof; and an emissive element disposed within the bore and in thermal contact with the forward portion.