You can use Electro Arc’s IQ precision disintegrating head to remove taps as small as #0. If you are a watchmaker you may have broken tiny taps that you are not sure how to remove. You can use a Electro Arc metal disintegrator equipped with the IQ head such as our model 2-SEQ or 2-SQT. You will want to special order small electrodes for your tiny tap sizes. You will also need a pin vice since the smallest electrodes that we make and sell are size .040.
The model 2-SEQ features the power supply and coolant tank/system built into a cabinet on wheels. The largest power supply available will be the 20 kva-rated machine, as is the case with all of our machines. This allows you to remove taps up to 2″ in diameter in a single pass. You can use it to remove bolts up to 1 1/4″ in diameter in a single pass. If you are not removing larger size taps, you can choose to step this down to our 10 KVA or 15 KVA option:
This machine includes our heavy-duty precision disintegrating head. This head allows you to disintegrate in small and large diameters. You can use the magnetic-based fixture that the head is mounted in on any ferrous surface. The model 2-SEQT and 2-SQT feature the auto-feed system, allowing you to run the machine hands-free. You have up to 9” of uninterrupted feed for hands-free operation. Feed rate potentiometer with two selectable speed ranges for precise control. Adjustable automatic shutoff, and auto-stop capability. Plug-in integrated circuit board for serviceability. The manual spring-loaded feed is standard on all machines and assists you in feeding the disintegrator head in a continuous movement. Use the depth stop and automatic shut-off features to concentrate on the disintegration progress, and take manual control with ou simple lever at any time! Use the depth gauge with adjustable depth stop and limit switch to set your machine for automatic shutoff at your desired depth. This helps you avoid damage to parts that do not have through holes.
The IQ precision head is available in full and short sizes for use with our fixtures.
Electro Arc's Model 2-SEQT
Electro Arc’s Model 2-SEQT features the IQ disintegrating head and also offers you the convenience of our smallest work surface, with a 19 X 19″ tabletop. You also have the convenience of the cross-arm structure. While the 2-SQT fixture offers versatility, the tabletop models offer a dedicated workspace. This machine is also easy to move around and has a small profile. You can use the IQ disintegrating head for disintegrating small taps weather it is on a portable model or a table top model.
Spark erosion is the process of vaporizing metal using a high-frequency spark discharge. Metal disintegrators are a subcategory of EDM, which is often referred to as Spark Erosion. Metal Disintegration Machining (MDM) is the process that Electro Arc machines use. These machines are specifically used to remove broken bolts, taps, pins, screws etc. quickly
"Spark Erosion" Applications:
Electro Arc Patented the Metal Disintegrator in 1942
If you are dealing with a broken screw, broken bolt, broken drill, or other broken tooling on a regular basis, you may have used a metal disintegrator to remove them. Metal disintegrators are specialized EDM machines originally patented in 1942 by Electro Arc. This broken bolt removal tool is essential in industries such as power generation, off-road vehicles, mining, aircraft repair, and automotive repair.
Remove your Broken Tooling wwth Metal Disintegration Machining
Spark eroders use the process of spark erosion, also referred to as spark machining, or die sinking to remove material from a part with electrical discharges. This modern machining process is responsible for many of the manufactured processes that exist today. Electrical discharge machining (EDM) has a long history which has led to significant breakthroughs in technology. While EDM has a variety of applications, MDM has the targeted ability to remove broken bolts, broken pins, broken drills, and other broken tooling in minutes. Although metal disintegrators are in a sub-category of Electrical Discharge Machining called Metal Disintegration Machining, the process is still considered spark erosion, hence the name spark eroder. Part of this name has to do with the sparks that are created by this process, erosion obviously refers to the process which allows broken tooling to be removed with these machines. The term spark erosion is more popular in countries like England and India. This term is used because the principal is more commonly understood under this name than “metal disintegrator”.
In fact, Electro Arc used the term to refer to our own machines between 2008 and 2018. Uni-Tek had a patent on the name “Tap-Zapper” which became associated with many of these machines as well. Electro Arc kept the patent for a short time but also used the term to describe many of our AC metal disintegrating machines. We find that these terms can be confusing and have made an effort to clarify each machine’s model and its features to help you choose the best metal disintegrator for your application.
We’re following up on the original article 10 ways you can use Electro Arc Metal Disintegrators with 10 more ways you can use these metal disintegrating machines! Electro Arc metal disintegrators are designed to quickly remove broken taps, drills, reamers, studs, screws, and other broken tooling from any material without damaging the threads or the workpiece. You can also emboss identifying marks on tools, dies, steel tools, cut oil groves inside bushings. Undercut recesses in hard machine parts, cut tool bit holes in boring bars, cut dogging squares, extend oil lines, and recenter hardened shafts. Check out additional applications illustrated below!
Your die shop can disintegrate round holes for dowel pins in die plates and cut intricate shapes for slug clearance in die shoes. You can salvage piercing dies where the piercing hole has been damaged or enlarged through wear and resharpening. Use the Electro Arc metal disintegrator to cut larger holes for inserting soft plugs so that locations may be picked up and soft plugs rebored for standard hardened die bushings. Disintegrate new holes in your die-casting dies where there has been insufficient coolant circulation. Emboss identifying letters on punch heads, minimizing the stock of heading punches you need to carry.
Your metal disintegrator will help you quickly and easily correct machining errors as shown above.
Use your Electro Arc metal disintegrator to relieve the bulk of metal in die sinking to keep displacement of metal to a minimum in hobbling the master.
Drill holes as small as .080 inches
Keyways are quickly and easily cut and enlarged in cutters, gears, bushings, etc.
With any angle access, create solutions for your engineering challenges.
Use your Electro Arc disintegrator to identify various metals in wear tests by disintegrating marks with different-shaped electrodes. You can core out test samples this way.
Cemented tungsten carbide can be drilled and counterbored for any size Allen head cap screw.
Also, provide threaded holes in carbides by disintegrating a hole of approximate size, fill it with brazing material, and drill and tap the hole to give it stronger threads with minimal time and investment.
Pierce blind holes and shaped holes in carbide and any material that conducts electricity.
The disintegrating process has a rapid heating and cooling process which leaves the Rockwell Hardness of the metal around the hole unchanged. Special electrodes can be purchased to pierce blind or through holes at any angle.
As Electro Arc machine owners, we understand that you need resources in addition to the owner’s manual you received with your metal disintegrator. As a company that has been producing metal disintegrating machines for 75 years, we know we have quite a few versions of our product in use with various stages of support needed.
Since Stillion Industries purchased Electro Arc, we have been striving to improve both the product and the support offered for these machines. Both of these processes are time-consuming and costly, so it has taken us a while to get to the point where we can produce new media to replace set-up and operation videos that are currently available. We have been offering new content through our YouTube channel to address common questions and demonstrate how our machines work.
We recently released a 30-page troubleshooting guide which addresses the most common issues machine owners may have with their metal disintegrator or disintegrating head. This guide is free of charge and is available for download in our store here on ElectroArc.com You may have noticed that a majority of the content from our troubleshooting section has moved. This is because we have created a new resource to assist existing machine owners.
We have also dedicated a new website to hosting all of the current setup and operation videos that we have for our metal disintegrators (yes, they are from the 90s) but they do cover the important points new machine owners may need to cover for training purposes. This website Metal-disintegrators.com is dedicated to providing a resource for machine owners through multi-media. We will continue to expand and improve the content available on this site.
D.C. cutting is direct current cutting, which is a naturally occurring process that moves metal from a positive pole (+) to a negative pole (-) when current flow is initiated (switched on) and subsequently interrupted (switched off). You may not know that this process is as old as the storage battery. It was also responsible for the problems of the early automobile ignition points and plugs – excessive wear on the positive terminals caused by the rapid switching of a D.C. circuit.
D.C. cutting is the basis for all convention and wire EDM machine technology (not to mention Electro Arc Metal disintegrators) and predates the electric light bulb.
DC Portable Metal Disintegrators Heavy-duty power for onsite or occasional use
How Does DC Cutting Work?
D.C. cutting or EDM cutting occurs when an ionized path is established (switched on) between a positive and negative pole and then broken (switched off) to stop the current flow. The simplest example is what occurs when the (+) and (-) poles of a car battery are momentarily (with jumper cables) touched together (switched on) and then pulled apart (switched off). When the cable clamps are examined you discover a crater on the positive clamp and an equal amount of material added to the (-) clamp – EDM in action!
Harness this D.C process to remove broken taps, drills, and bolts quickly and easily. Minimum heat is generated and low power is consumed because polarity is the major moving physical property. High amperage, can waste power as a violent arc is created generating excessive heat and causing extreme electrode wear.
How do Electrodes Work in the Metal Disintegration Process?
Did you know that any conductive material can be used as an electrode? The more conductive the electrode material, the more effectively an electrical process works, and this is an electrical process.
Electro Arc machines can be used with inexpensive copper tubing. Copper has superior conductivity (next to silver), low cost, and is easy to work with. It has the added benefit of being very conductive both electrically and thermally to aid in removing residual heat from the cutting area. We use other materials as electrodes for cutting operations where higher temperature arcs are required to remove high-temperature materials such as high-temperature bolts that are alloyed with molybdenum and other elements.
You need D.C. cutting because you are constantly searching for a better, faster, cheaper way to get your job done. D.C. cutting gives it to you because it moves metal faster through polarity while minimizing heat and power consumption through lower amperage requirements that always accompany the use of polarity as the major moving physical property.
How does D.C. cutting compare to A.C. cutting?
A.C cutting is the creation of a violent arc between a high melting temperature (molybdenum/melts at 4748 degrees Farinheight and 2620 degrees Celcius) electrode material and a lower melting point material (tool/steel/melts at 2500 degrees Farinheight and 1371 degrees Celsius) and the fact that the lower melting point material (steel) will melt faster than the high-temperature material (molybdenum). You will want to use DC current with carbide because it cuts faster than AC, you may also need a DC machine if you are planning to use your metal disintegrator on larger bolts.
Electro Arc’s AC metal disintegrators were the first metal disintegrators available on the market, released to the general public for purchase in 1947. While competitors came and went over the years, Electro Arc remained the best metal disintegrator manufacturer purchasing competing brands including Elox, AC machines are generally cheaper than DC machines and provide a larger variety of options for customization.
Electro Arc was formed in Detroit Michigan on May 26, 1947, by Harold W. Stark, who was a metallurgist/manufacturer and investment broker. Harold’s team patented the AC metal disintegrator in 1942. The metal disintegrators were originally branded as “boring machines” while patents were pending:
In 1949 Electro Arc moved its operations to Ann Arbor, running the business on the island across from Stark’s new residence, “The Castle” on Geddes Road. Nicknamed “The Castle”, this notable location was one of many properties associated with Ford’s close associate Harry Bennett. Stark purchased this unique property in a private sale offered by Bennett in 1948. The castle and Electro Arc stayed in the family, with Harold Stark’s eldest son, Harold Stark II taking over the business in the 1960s after his father passed away and moving his own family into the castle. The castle was sold in the 1970s but Electro Arc operations remained on the Island. Stark II moved the company operations to 161 Enterprise Drive in Ann Arbor, MI in 2008 in order to accommodate expanding operations. The company remained at this address until the company was purchased by Stillion Industries.
New promotions rebranded these machines as “Electro Arcs” and later “metal disintegrators” as they are currently known and referenced pending patents as the reason for limiting prior promotion of the Electro Arc product line. Electro Arc also merged with Syncro-cut Service Co, working closely with a large university’s engineering school as mentioned below:
Electro Arc continued on to release several new products increasing its product line to over 40 bespoke machines.
The F-5 Carbide Impregnator was introduced in mid-1964, this machine improves the life of drills, milling cutters, stamping and extrusion dies, lathe turning tools, slitting saws, form tools, taps, broaches, and punches by hardening wear surfaces of these tools.
The Model 3-S lightweight portable metal disintegrator was released in November 1964. This machine was designed to remove taps of any size, drills as small as .040 diameter without distorting the hole, it cuts shapes of any shape in hardened steel without distortion. We continue to manufacture and sell these machines. This machine was updated in February of 1966 to include a coolant tank base. Later the same year, the Model 1 metal disintegrator was released.
In 1967 and 1968 Electro Arc released the 2-SE and 2-S portable disintegrator models. The Model 2-S originally featured the LBH head which has since been upgraded to the arc-er head. This versatile disintegrating head can be chucked to any machining device at any angle (as shown above) and has a pull-out coolant tank designed for easy cleaning. The 2-SE has the features of the 2-S with the addition of a 20” x 19” cast iron tabletop featuring 3 T-slots.
Between 1969 and 1972 Electro Arc introduced several of its HK machines beginning with the HK-6, which at the time was the largest and most versatile table metal disintegrator available. This machine designed for extra heavy workpieces has a capacity of 8000 pounds, features a double-barrel 27-inch cross-arm which rotates 360 degrees and offers power feed which eliminates the possibility of human error.
In 2004 When Electro Arc purchased long-time competitor Uni-Tek, the metal disintegrator line doubled, now offering both AC and DC machines. DC models like the 2-SC and all of the DC tabletop models are perfect for disintegrating carbide. The X-1 and X-2 Extract All machines are portable and ideal for use onsite. The Bolt Eater provides heavy-duty cutting power with the servo head on a portable machine.
In 1975 Electro Arc began producing the Ames Portable Hardness Tester Line, introducing the Model 8 portable hardness tester in 1975, the tube hardness testing model ST in 1977, and offering a digital tester briefly in the 90s before discontinuing it. In 2000 the company upgraded from the wooden case for hardness testers to a high-impact case.
Both Starks purchased many companies during their commitment to Electro Arc, including metal disintegration companies Elox, Vibra’Arc, Marbaix, Jiffy, and Unitek. Ames joined the Electro Arc family in 1975, adding Ames Portable Hardness Testers to the Electro Arc product offerings. Stillion Industries is a family-owned machine shop which also began in Ann Arbor. Stillion Industries opened its doors to offer machining services in 1972. Originally started by Chuck Stillion, and now run by his son Keith Stillion, who moved the company to Dexter in 2014 after purchasing Dexter Manufacturing. Stillion Industries machined parts for Electro Arc for years before Keith Stillion purchased Electro Arc in July of 2019. Now, 97% of the parts for each portable hardness tester and 50-65% of the parts for every metal disintegrator are manufactured on-site here in Dexter, Michigan. We also continue to manufacture molybdenum electrodes, and other accessories for use with Electro Arc machines, offer repair and refurbishing services for Electro Arc and Uni-Tek machines, and provide calibration and repair services for the Ames Portable Hardness Testers in addition to selling Ames accessories including test blocks which are available for purchase on our website.
At its peak, Electro Arc maintained 4 international offices. Currently, Stillion Industries is our main headquarters with our United Kingdom office managing international sales for a number of countries not serviced by our home office. As Stillion Industries celebrates 50 years of machine shop service in the community, we also celebrate 75 years of Electro Arc, a company that has maintained local manufacturing of all of our products for the life of the company and continues to offer innovative solutions across industries. To commemorate this milestone for Electro Arc, we have created a timeline of the company’s milestones over the last 75 years available for you to explore. We are also offering a limited number of Ames model 1 hardness testers in the original wood box for sale on our website.
Merging with Electro Arc has been a huge undertaking for Stillion Industries and we strive to improve the notoriety of these durable machines with hopes to donate an Electro Arc’s old machine to The Henry Ford Museum. In the past, Ford had specially built metal disintegrators, and Ford Sr. was a friend of Harold Stark Sr. What a wonderful way to celebrate the history of this company and our hopes for years to come!
Electro Arc is the original manufacturer of Metal Disintegrators based in Michigan. The company’s founder, Harold Stark patented the AC metal disintegration process in 1942 and opened Electro Arc’s doors in 1947. Stillion Industries purchased Electro Arc in 2019 and carries on the quality name that Electro Arc metal disintegrators have become synonymous with.
Electro Arc Metal Disintegrators Last a Lifetime
You can see one of Electro Arc’s original paper promotions above, featuring the following models:
Model 2-S – Still one of our most popular portable models! This basic metal disintegrator now features our Arc-er Head and portable design which make it perfect for use in small shops.
1-S (See below) – The model 1-S was the largest table top metal disintegrator offered by Electro Arc initially.
2-SA – The model 2-SA was one of the first tabletop metal disintegrators offered by Electro Arc. This self-contained unit is great for high production plants and tool shops.
3-S – The model 3-S originally offered with no built-in coolant tank offers great portability for use in confined spaces.
Not shown on this flyer, the Carbide Impregnator was another flagship product Electro Arc was known for between the 1940s and 1970s. Electro Arc is the original and best manufacturer of metal disintegrators in the world. Our machines are known for their durability and long-lasting design. Now among over 40 configurations available, we are confident you will find an Electro Arc metal disintegrator is still the best value for your application!
The location and contact information is NOT correct in this vintage promotion
Over 75 Years of Michigan Manufacturing
As you can see, the original disintegrating head is different than our current Arc-er, IQ, and Servo disintegrating heads. The features of Electro Arc metal disintegrators are the same great features allowing anyone to use our machines. Electro Arc Metal Disintegrators have castors, the choice of AC or DC, and portable or tabletop, including the option to order a custom table top size. Most models allow you to choose your KVA power rating. Additional features include support options, head options, remote start/stop, and more!
In 2004, Electro Arc purchased Uni-Tek and integrated DC metal disintegrators into our product line. Our most powerful machine, the Bolt Eater represents the heavy-duty application of metal disintegration with both portability and the power to remove large bolts!
Stillion Industries is proud to carry on the Electro Arc Metal Disintegrator legacy in Dexter Michigan! We continue to improve the metal disintegrator design and offer repair and refurbishing services for old machines. Learn more about Electro Arc’s history.
Are you wondering what the best way to remove broken drill bits from metals is? Electro Arc has been providing high-quality broken tap, drill, stud, and bolt removal EDM / MDM machines since 1947. Our technology safely removes the broken drill in seconds without causing any damage to your part. Our spark erosion and metal disintegration technology can save you thousands of dollars by not causing damage to expensive parts. Please, take a moment to review how our spark eroders work.
Electro Arc’s unique process disintegrates only the center out of a broken tap or drill leaving its threads intact. You can use this process to cut square or round shapes to back out studs or bolts or to remove large studs with a series of cuts. Emboss identification on rolls of steel, bore, and counterbore holes. You can reclaim expensive parts and provide immediate repairs on all types of equipment. Thus you will experience fewer production overruns and late deliveries.
Electro Arc manufactures a full line of metal disintegrators both large and small, portables, table tops, AC and DC power supplies, and custom configurations to fit every application. Our AC power supply is ideally suited for hardened materials such as high-speed tooling. The DC power supply is superior at removing carbide tooling. We have multiple power supplies for removing taps as small as 0-80, and up to bolts/studs over 4” diameter in one pass. Our disintegrators are 10 times faster than other disintegrator manufacturers and are easy to operate.
You will find any of our small portable tap removers are far superior to the competitor. Our machines are built to last!
Supplies and Accessories The right consumables and add-ons
We can remove any type of metallic tooling, such as carbide or hardened steels, or any conductive metal part. Each of our metal disintegrators can use large-diameter electrodes. Our molybdenum (moly) electrodes have a higher melting point, which means you use less of an electrode in the process.
Our disintegrators come with everything you need to operate the machine including a coolant tank, pump, and motor plus free starter set of electrodes and collets. We offer portable magnetic base fixtures that use powerful permanent magnets for secure holding power.
All machines (including tabletop models) are built with cabinet-mounted wheels, handles, and/or usually lift eye rings for easy portability. To optimize portability, Electro Arc has put our disintegrators on heavy-duty trolleys. Everything you need goes with you in one convenient, easy-to-move cart, this includes a power supply, coolant tank, magnetic fixture, remote control, and lockable toolbox for storing electrodes and accessories for everything the operator will need on the job.
We offer multiple disintegrating heads available from small portable to larger heavy-duty heads with auto feed, servo feed, and manual feed options. Our disintegrating heads have been designed to handle the smallest and largest electrode. Our “in the quill head” or IQ delivers the precision and performance needed for small tap extraction to large turbine bolt removal. The Electro Arc head assembly is servo motor driven, hard-chrome finished quill and precision ground rack-and-pinion system. The Quill rides on the precision-honed bronze bushing, keeping .002” TOR tolerance. This provides smooth, positive, and accurate head feed. This is an exceptionally robust and accurate system that will provide a lifetime of trouble-free service. All our disintegrating heads can operate in any direction, including inverted or horizontal. All of our disintegrators come with a complete coolant system including a pump and motor and there is no need for a separate bath. Our disintegrators do not use an EDM dielectric fluid.
No need to submerse a part in dielectric fluid. Coolant is pumped through the head, and electrode directly to the point of disintegration, preventing heat distortion of your part, and also flushes disintegrated particles, which maximizes efficiency. We are the preeminent manufacturer of metal disintegrators. We have been building and designing easy-to-use, operator-friendly machines longer than any manufacturer in the world. All our machines are simple to operate, including easy to read current monitor/ammeter and no other gauges that need to be monitored.
Our disintegrators do not require an experienced operator. A competitor’s machine has warning indicators, pressure gauges, and several adjustments for the operator during and after the disintegrating process that are unnecessary and make operation more complex. Electro Arc has taken all these unnecessary problems and engineered the disintegrator to be worry-free. All our machines are high quality manufactured with warranties.
We have the ability to custom engineer machines for special purposes. Machines can be built to operate on nearly any input voltage. Machines can be CE or CSA-certified. Readily available parts and service to keep your machine operating for many years. Experienced staff provides the best-recommended solution and service for your individual needs.
All new machines include a minimum 1-year warranty. We do not use pneumatically (air) driven disintegrating heads, nor a mechanical swivel joint. Air is compressible and because air is compressible, it does not provide the kind of direct, mechanically positive characteristics of an electro-mechanical system. Therefore, the pneumatic system is prone to variations in either air pressure or coolant pressure. These variations in pressure cause the head movement to be erratic and choppy with less precision. Pneumatic systems are also prone to corrosion and other problems due to ingress of foreign particles and moisture. Electro Arc’s electro-mechanical system has none of these problems or exposures. We have an optional remote control with a start/stop or a remote that has all the machine controls. The operator should not have to fiddle around with adjustments to efficiently run the disintegrator.
We also have fixtures including a 3,000-pound permanent magnetic base which secures our rigid column and cross-arm. These hard chromed steel slides offer years of trouble-free service and there are no mechanical adjustments to make. One of our competitors uses an adjustable coolant pump with an alarm that alerts the operator if coolant pressure becomes dangerously high. The alarm gives the operator a chance to make pump adjustments before system failure. Electro Arc uses a factory-set pressure regulator, thereby eliminating the possibility of operator error with respect to the coolant pressure. Electro Arc (EA) machines do have an indicator light alerting the operator to any potential low coolant level.
A competitor’s machine has 8 axes of movement. Electro Arc’s machines has 7 axes of movement. Electro Arc’s machine positioning capability within the machine’s working envelope is identical to that of our competitor. Therefore, 8 machine movements are superfluous – adding the additional movement to machine complexity offers no functional reason, with more that can go wrong. We very much appreciate your consideration, and again, we believe that a thoughtful comparison of the disintegrators demonstrates that Electro Arc provides more value.
