Composite consumables for a plasma arc torch

1. An electrode for use in a plasma arc torch, the electrode comprising:

an elongated forward portion, defining a proximal end and a distal end, configured to provide an electrically conductive path from the distal end to the proximal end, the forward portion comprising a first conductive material with a first density;

a ring-shaped aft portion, defining a hollow center, configured to substantially surround and attach to a portion of the forward portion, a portion of the forward portion being located inside of the hollow center, the aft portion comprising a second conductive material with a second density, wherein the second density is at least two times less than the density of the first material;

an emitter disposed in the proximal end of the forward portion;

a contact element located at the distal end of the forward portion; and

a resilient element located between the contact element and the ring-shaped aft portion and physically contacting the forward portion, the ring-shaped aft portion coupling to the forward portion and adapted to move as one piece with the forward portion, the resilient element biasing the ring-shaped aft portion and the forward portion away from the contact element, wherein the resilient element passes at least a portion of a transferred arc current between a power supply and the forward portion via the contact element during a transferred arc operation of the plasma arc torch.

2. The electrode of claim 1 , wherein the ring-shaped aft portion includes a pneumatic reaction region for receiving a biasing flow of a pressurized gas.

3. The electrode of claim 1 , wherein the ring-shaped aft portion includes at least one fluid passageway for allowing passage of a gas therethrough.

4. The electrode of claim 1 , wherein the contact element comprises a third material.

5. The electrode of claim 1 , wherein the resilient element passes at least a portion of a pilot arc current between a power supply and the forward portion via the contact element during a pilot arc operation of the plasma arc torch.

6. The electrode of claim 1 , wherein the first conductive material comprises copper and the second conductive material comprises aluminum.

7. A plasma arc torch comprising:

an electrode comprising at least a forward portion, an aft portion, a contact element and a resilient element, wherein:

the forward portion including an electrode tip comprising a conductive first material, the electrode tip including: 1) a pilot contact region for initiating a pilot arc and 2) an emitter;

the aft portion, configured to attach to the forward portion, comprising a second material, the material density of the second material being at least half of the material density of the first material;

the contact element located at a distal end of the forward portion; and

the resilient element located between the contact element and the aft portion and physically contacting the forward portion, the aft portion coupling to the forward portion and adapted to move as one piece with the forward portion, the resilient element biasing the aft portion and the forward portion away from the contact element, wherein the resilient element passes at least a portion of a transferred arc current between a power supply and the forward portion via the contact element during a transferred arc operation of the plasma arc torch; and

a nozzle mounted relative to the electrode, the nozzle and the electrode defining a plasma chamber.

8. The plasma arc torch of claim 7 , wherein the electrode tip is cooled by a plasma flow through the plasma chamber.

9. The plasma arc torch of claim 7 , wherein the electrode further comprises a third portion coupled to a distal end of the aft portion, the third portion including a pneumatic reaction region for receiving a plasma flow.

10. The plasma arc torch of claim 7 , wherein the nozzle comprises at least a tip portion and a body portion, the tip portion comprising the conductive first material and the body portion comprising the second material.

11. A method of manufacturing an electrode usable in a plasma arc torch, the method comprising:

selecting a first conductive material having a first density and a second conductive material having a second density, wherein the second density is at least two times greater than the density of first material;

forming a ring-shaped aft portion from the first conductive material, the ring-shaped aft portion defining a hollow center;

forming an elongated forward portion from the second conductive material, the elongated forward portion defining a proximal end and a distal end;

fitting the elongated forward portion through the hollow center of the ring-shaped aft portion such that the ring-shaped aft portion substantially surrounds and attach to at least a portion of the forward portion;

locating an emitter in the proximal end of the forward portion;

locating a contact element at the distal end of the forward portion; and

locating a resilient element between the contact element and the ring-shaped aft portion, the resilient element physically contacting the forward portion, the ring-shaped aft portion coupling to the forward portion and adapted to move as one piece with the forward portion such that the resilient element biases the ring-shaped aft portion and the forward portion away from the contact element, wherein the resilient element passes at least a portion of a transferred arc current between a power supply and the forward portion via the contact element during a transferred arc operation of the plasma arc torch.