Electrode for plasma arc torch and method of fabrication
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United States of America Patent
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Jan 23, 2001
Grant Date -
N/A
app pub date -
Apr 29, 1999
filing date -
Apr 29, 1999
priority date (Note) -
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Abstract
An electrode for plasma arc torches has a tip body having a tip cavity with a cavity sidewall. An emissive insert having an insert sidewall resides in the tip cavity. A noble metal foil is interposed between the insert sidewall and the cavity sidewall. To fabricate the electrode, a tip body blank is provided, and a tip cavity having a cavity sidewall is formed therein. An emissive insert having an insert sidewall and being loosely insertable into the tip cavity is provided. The insert sidewall is provided with a textured surface with protuberances. A noble metal foil is selected, having an insert-contacting surface and a cavity-contacting surface. The emissive insert and the noble metal foil are placed into the tip cavity of the tip body blank, arranged such that the insert-contacting surface of the foil faces the insert sidewall of the emissive insert, while the cavity-contacting surface of the foil faces the cavity sidewall. After the emissive insert and the foil have been placed in the tip cavity, the tip body blank is placed into a die and radially deformed to compress the tip body blank and force the metal foil to conform to the textured surface of the insert sidewall. The deformed tip body blank is then machined to a final electrode configuration.
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