Metal Disintegration Accessories , Using your Metal Disintegrator

Black VS clear Splash bags for your metal disintegrator

What is a splash bag?

Electro Arc metal disintegrators use a thick clear or black “splash bag” to contain the coolant which is continually running through your Electro Arc metal disintegrator and the sparks metal disintegration process creates. This plastic bag is custom made to fit the area between the head of your metal disintegrator and the item you are disintegrating. Splash bags contain the coolant and shield the operator from sparks during the metal disintegration process. A splash bag is attached to the metal disintegrator head to cover the area you are disintegrating.

Electro Arc metal disintegrator set up with a black splash bag

The advantage to using a clear splash bag is that you can see the metal disintegration process, but this also means looking into the arc weld sparks produced during metal disintegration. However, as you are operating your Electro Arc metal disintegrator, your attention will be on the power controls and auto-feed functions so it is unlikely you will be looking directly at the metal harmful arc welding sparks anyway. The sound of your metal disintegrator will clearly indicate to you the progress that you are making with the disintegration job you are conducting and the process is quick, so there is no reason to be staring into potential eye harming arc sparks. Please note that we do not have clear splash bags available for purchase.

As weldors know, eye protection is required during the welding process because the infrared light can cause permanent damage to your eyes and lead to cataracts. The advantage to Electro Arc metal disintegrators is they do not require welding experience to operate. Anyone can learn to set up and use an Electro Arc metal disintegrator. Black splash bags provide protection for your eyes and eliminate the potential hazard to your eyes. We prefer the black splash bags here at Stillion Industries.

How many splash bags do I need?

If you are conducting regular metal disintegrating jobs with your Electro Arc metal disintegrator, you will likely use a lot of splash bags. You will need to use a splash bag each time you use the disintegrator. The good news is we sell them in packs of 50!

Do I have to use splash bags?

We highly recommend that you use splash bags to ensure the safety of the operator of your Electro Arc metal disintegrator.

Metal Disintegration , Metal Disintegration Accessories , Using your Metal Disintegrator

5 Steps to Choose the Machine You Need to Remove Broken Bolts

Try our Machine Builder

Our broken bolt, drill, and tap removal technology is the most cost-effective and precise method available in the market. Patented in 1942, AC metal disintegrators were made and distributed exclusively by Electro Arc for years before competitors entered the market. Electro Arc purchased Uni-Tek in 2004 and began making and distributing DC machines as well including the Bolt Eater. Electro Arc metal disintegration machines have been built in Michigan since the company began in 1947. These machines are known for their long-lasting design and easy-to-use configuration, allowing companies to apply the technology across industries.

See the Bolt Eater in Action:

You can use Electro Arc metal disintegration machines to quickly and easily remove the broken-off tap, drill, and or bolt without damaging your valuable equipment. In the infographic above, you can see the details of our precise spark erosion process. Please refer to the following recommendations to choose the right metal disintegrator for your needs.

How to choose the right metal disintegrator for your application:

Step 1. Do you need an AC or DC power supply?

Both AC and DC machines run 110 to 600 volts to vibrate AC machines make and break 50 or 60 times per second, while DC machines are at 120 times per second. DC power can maintain higher arc levels and sustain a larger arc. With DC machines you can use larger electrodes like square or hex-shaped carbon to drill faster and make larger holes.

Step 2. Next, which disintegrating head do you need? IQ, Servo, or Arc-er.

You can use the Arc-er head with our portable metal disintegrators and you can use it directly with machines like a Bridgeport. The IQ head provides faster-cutting speed and can be used with larger electrodes. You will receive a Servo head with our DC machines.

Step 3. Do you want a Portable or Table top machine?

Portable machines are great for on-site application. If you need to take the metal disintegrator to the part, a portable metal disintegrator is for you. Off-road vehicle repair, mining operations, submarines, and repairs on the line are some great examples that would benefit from a portable machine.

You will want a tabletop machine if you are working on parts that can be taken to the machine for disintegration. We offer tabletops ranging in sizes and can create custom table tops if needed.

Step 4.

Which electrode do you need?

We offer electrodes made of graphite, copper, and molybdenum. Depending on the hardness of your piece, you will want to choose the appropriate electrode. Please refer to our sizing charts to choose the best one for your needs.

Metric Starter Set

$532.50

Add to cart
Standard Starter Set

$532.50

Add to cart

Step 5. What kind of material are you working with?

If you are working with carbide, you will want to choose a machine with “C” in the model number such as our 2-SEC which is a more compact tabletop machine offering the durability and power to disintegrate carbide.

Check out one of our DC Table Top Demonstrations:

Metal Disintegration , Metal Disintegration Accessories , Using your Metal Disintegrator

Electrodes For Tap & Drill Disintegration

Molybdenum Electrodes Are Different

These Electrodes are different and are usually less expensive. Moly electrodes have a higher melting temperature which means that it will break down or erode more of the broken tool, tap, or drill rather than the electrode.

For Molybdenum Electrodes the diameters start at .020″

Looking for electrode diameter sizes?

VIEW LISTING OF STANDARD ELECTRODE DIAMETER SIZES

Graphite Electrodes

Graphite has several advantages over other materials. It is resistant to thermal shock. It is the only material in which mechanical properties increase with temperature. It has a low CTE for geometrical stability. It is easily machined. It does not melt but sublimes at very high temperature (3,400ºC), and finally, its density is lower (five times less than copper) which means lighter electrodes. Graphite removes material better than copper or copper-tungsten while wearing slower. The wear rate tends to diminish as the discharge increases, unlike copper, whose wear increases at higher currents. Therefore, graphite is suited for the machining of large electrodes since working with a high current intensity provides decreased roughing time.

Although graphite is prone to abnormal discharge, this can be eliminated through quality flushing, and lowering the intensity of discharge during negative polarity machining. However, as a result of this tradeoff, machining tungsten carbides is more difficult than with copper-tungsten electrodes. Also, since graphite is a ceramic, it is sensitive to mechanical shock, and consequently must be handled and machined with care.

For Graphite Electrodes the diameters start at 3/8″(9.5 mm)

For Graphite Electrodes the minimum power supply requirements are 15 KVA or higher

VIEW LISTING OF STANDARD GRAPHITE ELECTRODE DIAMETER SIZES

VIEW GRAPHITE ELECTRODE HOLDERS

Help With Electrode Sizing

View Instructions

Always Make Sure To Pick The Right Type Of Electrode

Molybdenum (Moly) Electrodes

Moly Electrodes have a higher melting temperature which means you will erode more of the broken tool and less of the electrode making Moly less expensive to use than other materials.

Graphite Electrodes

When removing large bolts .750″ to 19 mm and up use Graphite Electrodes for optimum performance and value. Graphite Electrodes only work on metal disintegrators with 20KVA or DC power supply.

Square, Hex, and custom Graphite Electrodes are available upon request.

Category Metal Disintegration Accessories