James Maloney, Independent Researcher Manchester, NJ, USA
Electrode erosion and arc instability remain major limitations in plasma cutting and welding systems, where conventional pointed or recessed electrodes concentrate arc attachment at a single location [1], [2]. This localized heat flux accelerates material loss, degrades cut and weld quality, and increases consumable replacement frequency [3]. This work investigates a toroidal electrode geometry designed to promote distributed arc attachment through curvature-driven sheath shaping. The toroidal boundary forces the plasma sheath to form a continuous annular structure, reducing local electric-field intensification and spreading the arc root over a larger surface area [4], [5]. As the electrode reaches thermal equilibrium, the sheath undergoes a uniform thermal expansion that lifts the attachment zone slightly away from the surface, further reducing direct metal evaporation [6], [7]. A prototype toroidal electrode was evaluated against a standard pointed electrode under identical operating conditions. Measurements show improved arc stability, reduced voltage fluctuation, lower erosion rates, and more consistent cut and weld quality [8], [9]. These results demonstrate that electrode geometry can be used as a practical and manufacturable method for enhancing consumable life and process reliability in industrial plasma systems.
Plasma cutting, Plasma welding, Arc attachment, Electrode erosion, Toroidal electrode geometry
Copyright © ME 2026