Composite electrode for a plasma arc torch
First Claim
1. A plasma arc torch comprising:
- a torch body for holding an electrode, the torch body including a plasma flow path for directing a plasma gas to a plasma chamber;
a composite electrode; and
a nozzle mounted beneath the composite electrode, the nozzle and the composite electrode defining the plasma chamber, wherein the composite electrode comprises;
an electrode body having a forward portion and an aft portion, the aft portion comprising a first metallic material and having a first mating surface;
the forward portion comprising a second metallic material and having a second mating surface configured to join with the first mating surface such that an interior surface of the forward portion is directly cooled by a coolant, the first and second mating surfaces being in direct contact with each other;
wherein the first and second metallic materials have a heat transfer property, the value of the heat transfer property for the second material being greater than that of the first metallic material.
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Reexamination
Accused Products
Abstract
A plasma arc torch that includes a torch body having a nozzle mounted relative to a composite electrode in the body to define a plasma chamber. The torch body includes a plasma flow path for directing a plasma gas to the plasma chamber in which a plasma arc is formed. The nozzle includes a hollow, body portion and a substantially solid, head portion defining an exit orifice. The composite electrode can be made of a metallic material (e.g., silver) with high thermal conductivity in the forward portion electrode body adjacent the emitting surface, and the aft portion of the electrode body is made of a second low cost, metallic material with good thermal and electrical conductivity. This composite electrode configuration produces an electrode with reduced electrode wear or pitting comparable to a silver electrode, for a price comparable to that of a copper electrode.
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Citations
51 Claims
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1. A plasma arc torch comprising:
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a torch body for holding an electrode, the torch body including a plasma flow path for directing a plasma gas to a plasma chamber;
a composite electrode; and
a nozzle mounted beneath the composite electrode, the nozzle and the composite electrode defining the plasma chamber, wherein the composite electrode comprises;
an electrode body having a forward portion and an aft portion, the aft portion comprising a first metallic material and having a first mating surface;
the forward portion comprising a second metallic material and having a second mating surface configured to join with the first mating surface such that an interior surface of the forward portion is directly cooled by a coolant, the first and second mating surfaces being in direct contact with each other;
wherein the first and second metallic materials have a heat transfer property, the value of the heat transfer property for the second material being greater than that of the first metallic material. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14)
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15. A composite electrode comprising:
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an electrode body having a forward portion and an aft portion, the aft portion comprising a first metallic material and having a first mating surface;
the forward portion comprising a second metallic material and having a second mating surface configured to join with the first mating surface such that an interior surface of the forward portion is directly cooled by a coolant, the first and second mating surfaces being in direct contact with each other;
wherein the first and second metallic materials have a heat transfer property, the value of the heat transfer property for the second material being greater than that of the first metallic material. - View Dependent Claims (16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34)
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35. A method of manufacturing an electrode, comprising the steps of:
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providing an aft portion of an electrode body comprising a first metallic material and having a first mating surface;
providing a forward portion of the electrode body comprising a second metallic material and having a second mating surface configured to join with the first mating surface, wherein the first and second metallic materials have a heat transfer property, the value of the heat transfer property for the second material being greater than that of the first metallic material; and
directly welding the first and second mating surfaces to form a joint. - View Dependent Claims (36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50)
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51. A method of cooling a composite electrode comprising:
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providing an electrode comprising a body having a forward portion and an aft portion, the aft portion comprising a first metallic material and having a first mating surface, the forward portion comprising a second metallic material and having a second mating surface configured to join with the first mating surface;
directly contacting the first and second mating surfaces with each other; and
circulating coolant across at least one interior surface of the forward portion to cool the electrode.
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Specification