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Tag metal disintegration

Why are Metal Disintegrators Sometimes Called Spark Eroders?

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.

Comparing Electro Arc disintegrating heads

Electro Arc’s Arc-er portable disintegrating head

Arc-er Head in action

The Arc-er head is ideal for portable use. You can use it with portable or tabletop metal disintegrators. You can also use the Arc-er head with machine tools like CNC machines, Bridgeport, Radial drill, lathe or mill, and directly on the workpiece. This head operates at any angle. You can remove broken tooling from .079 to 3/4 inches in a single pass.

The Arc-er head is standard with the following machines:

2-S
2-SB
2-SE
2-SET
2-SA
3-S

In September of 1998, the Arc-er head was introduced as an upgrade for the previous LBH head. Although similar in design and use, the Arc-er head features an LED current monitoring system to assist you in maintaining optimal use of your Arc-er head and saves on electrode consumption.

You can also purchase the ultra-compact mini-mag 800 lb fixture or the portable magnetic base fixture which attaches to ferrous surfaces and provides 3000 lb holding power for use with your arc-er head. You can expect reliable heavy-duty service with your Arc-er Head which is designed to remove taps, drills, and studs up to 1″ diameter.

Electro Arc’s IQ Precision Disintegrator Head

IQ head on our test stand

The IQ precision disintegrator head is a high-performance head engineered for heavy-duty use. You can use this head horizontally or vertically. Thermal protection prevents any potential damage from overheating. You can use the IQ head to remove taps, bolts, drills, and fasteners up to 1″ in a single pass.

The IQ head is a standard feature for the following metal disintegrators:

2-SQT

2-DV

2-DVQ

2-DVT

2-DVQT

1-SV

1-SVT

1-SVQ

1-SVQT

HK-6V

The IQ head body enables smooth movement with 9″ of manual or automatic travel. This head is ideal for small taps from 0-80 or extremely large taps such as 2-inch taps or larger bolts such as 1 1/4-inch bolts and up. If you need to disintegrate carbide, look at the Servo head below:

Electro Arc’s Servo Disintegrator Head

Servo Head test burn

A high-performance disintegrating head, engineered for heavy-duty precision use. You can use this with electrodes from .020 inches to 1-inch diameter. You can use this machine to take out broken tooling including taps, bolts, drills, fasteners, etc. from 2# diameter in a single pass. Larger diameters are handled with multiple passes.

The Servo DC disintegrator head is standard on all of our DC machines.

We offer the full-size servo disintegrating head and a mini servo disintegrating head. The servo head is specially designed for heavy-duty use and comes standard with our most powerful machine, the Bolt Eater. This head disintegrates broken bolts 2 inches or larger. The mini servo DC disintegrator head is ideal for portable disintegration giving you ease of use at all angles and in small spaces.

Not sure what disintegrating head is best for your application? Try out our Machine Builder!

Why Do I Need DC Cutting?

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.

What is the History of Electro Arc and EDM?

When you search for the term “metal disintegrator” you will likely find ‘Electrical discharge machining’ as a result.  That is because the technological breakthrough that led to metal disintegrating machines was spearheaded by a team including Harold Stark who went on to patent the idea for AC metal disintegrators and started the world’s first metal disintegration machine factory in Detroit Michigan.  This process is metal disintegration machining (MDM).

You may have heard Electrical discharge machining, EDM for short, called spark machining, arc machining, and spark eroding.  This is a non-conventional group of machining which now includes electrochemical machining, water jet cutting, and laser cutting.  This process is limited to use with ferrous alloys because it requires the base material to be electrically conductive.  A solution for high-accuracy, complex machining applications provides an efficient alternative where other methods are impossible.  Using an electrical current, spark discharge erodes the workpiece using dielectric fluid as an electrical insulator. There are three main forms of EDM, wire EDM, die sinker EDM, and hole popping EDM.  

EDM is usually associated with the wire EDM machine method which was developed between the 1960s and 70s to make dies from hardened steel.  This EDM process uses wire wound between two spools of wire creating two electrodes, the tool-electrode, and workpiece-electrode, which are separated by dielectric fluid. With increased voltage, the fluid produces an electric arc. The wire moves in a controlled pattern and sparking occurs between the wire and the workpiece.  This method removes excess material with automated technology similar to CNC providing high accuracy and precision.  Commercial wire EDM capability has continued to advance substantially over the last few decades.

Joseph Priestly originally discovered the erosive effect of electrical discharges in 1770.  Die sinker EDM was invented independently by two groups.  In 1943 two Russian scientists Boris and Natalya Lazarenko were exploring methods to increase the lifespan of tungsten breaker points. Their research led to the discovery that erosion could be precisely controlled if the electrodes were immersed in dielectric fluid. This allowed the invention of an EDM machine tool for processing hard materials like Tungsten. This tool became known as a resistor-capacitor (R-C) circuit for EDM.  

During this time, without knowledge of the experimentation taking place in Russia, a team of American scientists consisting of Harold Stark (the founding president of Electro Arc), Victor Harding and Jack Beaver were also developing a method to remove broken drills and taps from aluminum castings.  This team was tasked by their employer with finding a solution because tools were being broken off in expensive aircraft parts.  Initially constructing machines from electric etching tools, they were unsuccessful.  After trying compressed air, they added fluid to the machines, combined with spark repetition allowing them to cut through metal quickly and efficiently while the coolant flushed away metal particles created in this process. Their research was able to produce 60 sparks per second, a breakthrough in technology at the time. Machines initially developed by this team were used during World war II and the trio patented the system for removing broken bolts, taps, and drills as well as an electronic-circuit servo system that maintained proper spacing between the electrode and the workpiece.

This led Harold Stark to develop Electro Arc’s Metal Disintegrator line of metal disintegrating machines which are still produced by Stillion Industries today (Stillion Industries purchased Electro Arc in 2019).  This technology was key in the development of vacuum tube EDM machine tools capable of producing thousands of sparks per second (electric discharge machining) in the 1960s.  Die sinker EDM machines are traditionally used to create three-dimensional shapes.  EDM provides an advantage because the process is predictable and accurate, making it easy to reproduce, but it is slower than other methods.

Hole drilling EDM is a specialized hole-making machine sometimes called a “hole popper” which is used to create the pilot hole necessary for wire threading. Using thermal energy rather than mechanical force, these machines cut through extremely hard materials such as titanium, carbide, carbon graphite, and high alloy steel.  These machines work on the same principle as wire EDM machines.  Instead of wire, these machines use a tool that works like a drill bit, no physical contact takes place between the tool and the workpiece, the electrical discharge is conducted to rapidly cut the metal.  This process is ideal for extremely small holes, as small as 0.010”. 

In his book, ‘Electrical Discharge Machining’ Elman C. Jameson mentions working with Victor Harding and Harold Stark during the origination of the EDM process in the United States.  EDM became popular in Japan as a result of damage from the war.  This new method was key in rebuilding after the destruction of their infrastructure.  On the other hand, The existing equipment and workers in the US caused a delay in the acceptance of EDM technology in the US.  Electro Arc metal disintegrators are an appealing option because they do not require special training for operators as other EDM machines require.

Electro Arc Metal Disintegrators made in Michigan since 1947

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.

Electro Arc Portable AC Metal Disintegrators

Setting the Record Straight With Metal Disintegration Machining | Terminology

In the industry of metal disintegration machining, oftentimes there is misinformation about the terminology that is used to describe the machines, parts, and processes. We at Electro Arc Manufacturing are here to show you what is what when it comes to metal disintegration. Below are terms and proper definitions for processes and machinery-related items in the world of metal disintegration.  People in different areas use different terms to refer to our machine process. Some are misleading.  For our process, a real arc is essential. We don’t burn the material; we vaporize it to turn it into particles.

“EDM” is the correct term for a very different process. Electric Discharge Machining is much more precise than arc disintegration but also very slow. EDM machines are also MUCH more expensive. On the other hand, “MDM” stands for Metal Disintegration Machine, which is what we build. Terms like “spark eroder, spark erosion, spark burner, or spark disintegrator” are misleading and incorrect. Aside from superficial campfire embers, sparks are relatively low-power, momentary electrical effects like those in automotive spark plugs to ignite fuel. By contrast, our arc is a powerful current path operating at very high temperatures like in carbon-arc searchlights. Our arc process literally vaporizes the metal to be removed in a controlled way.
Metal Disintegration Machining (MDM)

Metal Disintegrators or MDM machines are manufactured for the specific purpose of removing broken tools from workpieces. The metal disintegration process removes a tap, bolt, or drill leaving the hole intact and allowing a part to be reclaimed.  MDM removes material very fast. MDM uses a spark erosion process commonly used for destructive cutting. Typical application includes broken tool extraction (taps, drills, reamers, drill bits) metallurgical sample excavation, and bolt removal. There is no faster or efficient or cost-effective method to remove broken tools, studs, or fasteners than MDM.

 

Electrical discharge machining (EDM), also known as spark machining, spark eroding, die sinking, wire burning or wire erosion, is a manufacturing process whereby a desired shape is obtained by using electrical discharges (sparks). Material is removed from the workpiece by a series of rapidly recurring current discharges between two electrodes, separated by a dielectric liquid and subject to an electric voltage. One of the electrodes is called the tool-electrode, or simply the “tool” or “electrode,” while the other is called the workpiece-electrode, or “workpiece.” The process depends upon the tool and workpiece not making actual contact.  When the voltage between the two electrodes is increased, the intensity of the electric field in the volume between the electrodes becomes greater than the strength of the dielectric (at least in some places), which breaks down, allowing current to flow between the two electrodes. This phenomenon is the same as the breakdown of a capacitor (condenser) (see also breakdown voltage). As a result, the material is removed from the electrodes. Once the current stops (or is stopped, depending on the type of generator), the new liquid dielectric is usually conveyed into the inter-electrode volume, enabling the solid particles (debris) to be carried away and the insulating properties of the dielectric to be restored. Adding new liquid dielectric in the inter-electrode volume is commonly referred to as “flushing.” Also, after a current flow, the difference of potential between the electrodes is restored to what it was before the breakdown so that a new liquid dielectric breakdown can occur.

Spark Erosion

Spark erosion is sometimes miscommunicated as being metal disintegrating but it is not. Spark erosion is a form of EDM or electric discharge machining that is a machining technique principally used for hard metals and metals that are difficult to machine using traditional methods. EDM normally operates with materials that are electrically conductive and is designed to erode (remove) intricate depressions or contours from pre-hardened steel negating the requirement for heat treatment to soften and re-harden the steel. We use this method on many different types of metals and alloys, such as Monel, Titanium, Tool Steel, Tungsten Carbide, Tantalum, Super Duplex, and Inconel.

Learn more about the spark erosion process.

Spark Eroder, Spark Burner, or  Spark Disintegrator (You may have heard these referred to as Metal Disintegrators)

Our metal disintegrators are sometimes referred to as Spark Eroders. This is a common term used throughout the UK. However, spark eroders produce sparks in the application, and metal disintegrators do not. So spark eroders are the machines that are used in the electric discharge machining field.

Metal Disintegrator

Metal disintegrators are primarily used for bolt removal, tap removal, stud removal, drill removal, and seized or broken bolts. The process can also be used for roll marking or branding for rebar identification, tool and die work, and metallurgical core sampling. The cutting action of a metal disintegrator is accomplished by creating a series of intermittent electric arcs that break down the hardest metals into minute particles. An electrode, held in the head of the disintegrator, vibrates as it cuts while coolant is pumped through the electrode to wash away the powdered metal.

Metal disintegrators or Metal Disintegration Machining (May be abbreviated as MDM in the machining industry) are primarily used for bolt removal, tap removal, stud removal, drill removal, and seized or broken bolts. Other terms used to describe these machines include bolt eater, tap zapper, and stud buster.
 
Stillion Industries Acquires Electro Arc Manufacturing

Exciting news for our customers!

As of July 1st, 2019, Stillion Industries has acquired Electro Arc Manufacturing. This is good news for our customers. Alongside Stillion Industries, Electro Arc now has state-of-the-art ISO 9001:2015 compliant machining and on-site engineering. With Electro Arc’s long history of quality product lines and Stillion Industries’ expertise in machining, we are positioned to make both companies reach new heights.

The move coincides with the retirement of Harold Stark, Electro Arc’s President/CEO since 1958, and ensures the continuation of Electro Arc’s tradition of quality.  Stillion Industries, active in the Ann Arbor area since 1972, brings expertise in machining as well as manufacturing know-how from Dexter Manufacturing Incorporated, which joined Stillion in 2014.

We have retained all employees from Electro Arc, doubling our workforce to maintain the long history and experience of both companies. Electro Arc has been in the Ann Arbor area since 1947 Stillion Industries since 1972. Electro Arc Manufacturing includes the Ames Hardness Tester and Uni-tek metal disintegrator product lines. The acquisition will ensure we are here to stay and we are committed to customer service.  We at Stillion Industries feel Electro Arc, Ames, and Uni-tek are time-tested superior products. We are committed to providing great customer service and a high quality
product.

We look forward to your ongoing valued business as we continue to provide a quality product.

Stillion Industries

Keith Stillion
President

What is the Spark Erosion Process?

Imagine you’re on the production line working on a large manufacturing machine. Everything seems to be running smoothly, until crack, a tap has broken off in the machine. A person breaks the tap, not the machine.

Unable to retrieve the broken piece without damaging the machine or stripping the threads of the casting, you are left with two options. You can replace the broken machinery, which comes at a high cost and slows productivity, or you can apply spark erosion, solving your problem in seconds rather than hours or days and for a quarter of the cost.

Spark erosion, metal disintegration, electrical discharge machining; if you work in any industry that utilizes machinery you’ve probably heard one or more of these terms. Each of these titles is used to explain the process of removing metal using electric currents under carefully controlled conditions.

How does the spark erosion process work?

While (EDM) spark erosion can be used to create specific metal parts, it is also commonly used to remove broken drill bits, taps, bolts, and studs from within a machine casting without damaging the threads or casting itself. This is called MDM.

Spark erosion is conducted through metal disintegration machines (EDM). These machines use electrodes to send low voltage/ high current electrical charges that melts the designated piece of metal at the same time cold water thermal shocks the molten steel and pulverizes it into micro-size pieces and flushes it away.

Because there is no direct contact between the electrodes and the machine casting, spark erosion allows you to work with even the most intricate sections and weak materials without risking distortion. It is this precision that makes spark erosion the most effective way to salvage parts that would otherwise be deemed unusable.

Five steps to applying spark erosion

Step 1: Get your metal disintegration machine ready. Electro Arc has a variety of options to choose from depending on your need, including portable, table top, and specialized metal disintegrators.  Use our new Machine Builder if you are not sure which machine is best for your application.

Step 2: If you are using a portable machine, attach the provided portable electrode head to your drill press, CNC machine, lath, or any type of machine tool.

Step 3: Align the electrode to ensure it’s centered over the object you plan to remove and lower the splash bag.  Verify that the bolts are tight. Each machine comes with a splashguard mechanism for safety purposes in order to keep sparks contained and prevent eroded metal from flying.

Step 4: Switch on the power supply. Portable metal disintegrators come with a small, rolling power supply cabinet that is easily transportable. The power supply features a built-in coolant tank and heat selector knob. For easy usability, all machines come with a chart that directs you on exactly which heat setting to use for each size broken tap or drill that you’re planning to remove.

Step 5: Turn the heat selector knob to the desired temperature and begin the process. Within seconds, the MDM machine will finish its cut. You can then clear the hole of any remaining debris using the provided air compression tool and see that your part has been completely recovered, casting, and threads left unscathed.

Yo can see the Electro Arc process in action, with video tutorials and case studies on Electro Arc’s YouTube Channel.  Since Stillion Industries purchased Electro Arc in 2019, we have created a new channel with updated videos as well.

Advantages of using spark erosion machines

In a previous blog post, we discussed the many benefits of using Electro Arc’s spark erosion machines, some of which include:

  •      Simple operation
  •      Unbeatable price
  •      Relatively lightweight and easy to maneuver
  •      Quick setup and breakdown
  •      Easily manageable for one person
  •      Little-to-no maintenance; simply keep it filled with fresh coolant

Spark erosion is the fastest and most cost-effective solution to recovering machinery that has been compromised by broken tools. For 75 years, Electro Arc has been perfecting this process and supplying premium metal disintegrators at affordable prices throughout the world.

You can see lots of broken bolt removal examples which illustrate how an Electro Arc metal disintegrator will benefit your company and save you money.

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How to Remove Broken Drill Bit From Metal

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.

Examples of disintegration with an Electro Arc metal disintegrator

Get the Job Done Right with Electro Arc

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.

Model 2-SQT for removing broken drills:

  • Unlimited disintegration potential in a compact, versatile package 
  • For HSS tooling removal
  • Remove taps, drills, and studs from 0-80 to 2” (24.5 mm) in a single pass
  • The 36-inch maxi feature provides ultra-rigid support for absolute positioning

See more videos
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