The Electro Arc Process Removes Broken Tooling Fast
When using Electro Arc AC machines, consider the following:
Power and Capability
3 KVA power supply will disintegrate taps up to 10mm in one pass. (Use a .187” electrode)
10 KVA power supply will disintegrate taps up to 22mm in one pass. (Use a .375” electrode)
15 KVA power supply will disintegrate taps up to 32mm in one pass. (Use a .625” electrode)
20 KVA power supplies are used for larger taps, bolts, and fasteners.
Note: Depending on the power supply, multiple passes may be the fastest and most economical way to remove the broken tool.
Time Studies Using Electro Arc Model 2-DVQT equipped with 20 KVA power supply:
Drill Size: .217 ”
Hole depth: 1 ”
Electrode Diameter: .140 ”
Heat Range: #5
Depth of disintegration: 1.0”
Time of disintegration: 1:45 minutes
Molybdenum electrode consumption: 1 “
Drill Size: .160 “
Hole depth: 1 ”
Electrode Diameter: .110 ”
Heat Range: #4
Depth of disintegration: .250 ”
Time of disintegration: 0:40 Seconds
Molybdenum electrode consumption: .187 ”
The drill used for the 5mm was undersized. The best I could do was to get the bolt .300” into the hole before the bolt snapped off. I am confident that it really did not matter. The results would be the same. The bolt comes out with ease.
The above off-road vehicle was brought back online when a 2-DBQT was used to disintegrate a broken bolt. This isn’t the kind of machine that can afford to be offline!
The 2-DBQT is now the 2-DVQT, See it in Action:
All of these car parts had broken bolts removed in minutes! Check out the video below for an example: You can also remove a broken drill from a manifold.
DC Metal Disintegrator Examples:
Time Study DC Metal Disintegrator
Drill Size: .290 ”
Hole depth: 1.5 ”
Electrode Diameter: .187 ”
Heat Range: #7
Depth of disintegration: 1.0 ”
Time of disintegration: 2:10 minutes
Molybdenum electrode consumption: .312 ”
The Bolt Eater is our Most Powerful Metal Disintegrator
Designed specifically to remove broken bolts 1/2″ and larger, you can use the Bolt Eater to remove 1″ bolts 4″ deep in 20 minutes.
Remove 1.5″ bolts 4″ deep in one hour.
Remove 2″ bolts 4″ deep in two hours.
Remove 3.75″ bolts 6″ deep in 5 hours. This heavy-duty machine is built to run continuously so you can remove big broken bolts as quickly as possible. No other machine compares to the Bolt Eater for removing large broken tooling. Disintegration is the best and safest way to remove large broken bolts. It is fast, efficient, and safe.
1) 3” diameter by 3” long stud or bolt
2) 1.250” by 6” Graphite Electrode
Note: In this sample, we will disintegrate three holes in a clover leaf configuration. This will show how the large bolt is cut into sections for easy removal.
1) 2” diameter by 3” long stud or bolt
2) 3/8” thick by 1” long x 1” wide Slitting Graphite Electrode with 6” extension.
Note: This sample will demonstrate slitting capabilities separating the bolt into two pieces for ease of removal.
1) 1 “ diameter by 3” long stud or bolt
2) .735” square x 6” long Coreless Graphite Electrode
Note: This sample will show how square holes can be disintegrated and the use of drivers can be used to back out the broken fastener. If the driver does not work, the bolt walls are collapsed to the center and easily removed.
3) 1 “ diameter by 3” long stud or bolt
4) .750” round x 6” long Graphite Electrode
Note: This sample will show how a hole can be disintegrated and the use of an easy-out can be used to back out the broken fastener.