Angled Plasma Gouging Torch Nozzle
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
General-purpose plasma arc torches have limitations in gouging deep grooves in metal workpieces, particularly when backgouging the roots of welds in thick plates, as they often contact the workpiece at shallow angles, restricting the depth of the gouge.
Innovation Solution
A specialized plasma arc torch with an angled nozzle that allows orientation at steep angles, featuring a non-axisymmetric distal portion and a unique bore structure, enabling deep gouging without contacting the workpiece, and optionally incorporating a secondary gas for cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a general-purpose plasma arc torch is oriented at a shallow angle (25° to 40°) to the workpiece surface, then the torch can operate stably, but the depth of the gouge is limited before the torch contacts the workpiece
Solution Approach 1:
The nozzle is designed with an asymmetric angled configuration where the bore axis is offset from the electrode axis by a specific angle (e.g., 20 degrees). This asymmetric geometry allows the plasma arc to be directed at an optimized angle to the workpiece surface, enabling deeper gouging operations while maintaining torch stability and preventing contact between the torch body and workpiece.
2Length of moving object
If the nozzle bore is drilled at an angle to create the angled plasma flow, then deep gouging is enabled, but thin easily melted edges are created at the bore exit
Solution Approach 1:
The nozzle design incorporates local quality variations through its asymmetric geometry, where the bore cross-sectional area and wall thickness are strategically distributed. The thicker regions provide structural strength and heat resistance at critical locations, while the angled configuration directs the plasma flow appropriately. This localized optimization prevents edge melting while maintaining the ability to perform deep gouging operations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables deeper gouging operations without torch contact, facilitating the removal of metal from thick plates by directing the plasma arc at a controlled angle, enhancing the torch's capability to create deep grooves effectively.
Implementation Method 1
The electrode assembly extends along an axis of the electrode and terminates at a front face of the electrode at which the emissive insert is positioned for emitting an arc that passes through the bore of the nozzle and attaches to a metal workpiece during a transferred-arc mode of operation of the torch
Implementation Method 2
a plasma arc torch adapted for gouging a metal workpiece comprises a torch body assembly defining a passage for flow of a plasma gas supplied to the torch
Data Source
AI summary
A special-purpose plasma arc torch for gouging grooves in a metal workpiece includes an angled nozzle having a bore made up of a first bore portion and a second bore portion that makes an angle of about 15° to about 75° with the first bore portion. The nozzle includes a proximal portion and a distal portion, the proximal portion being adapted for surrounding an electrode assembly when the nozzle is installed in the torch, the distal portion being adapted such that a part of the distal portion extends beyond a front face of an electrode of the torch. The part of the distal portion extending beyond the front face of the electrode has an exterior shape other than cylindrical or conical, and preferably has a non-axisymmetric shape that makes it suitable for fitting within a deep groove in a workpiece.