If you are considering a metal disintegrator purchase, you have a lot of choices to make regarding which machine is best for your application. Electro Arc manufactures over 40 models of metal disintegrators. You will want to choose between a portable or tabletop model. Portable models are great for disintegrating on large parts. You can choose an AC or DC model. If you are choosing the AC option you will also need to decide what KVA you want your machine to be. Your KVA choice will determine how large a diameter you can disintegrate. Below is a guide to help you choose the correct KVA for your application:
As you can see, choosing your KVA has everything to do with the disintegration you are planning for. If you will only be disintegrating under 3/8″ taps and drills, a 3 KVA model will work out for you. One of our most popular portable models is the model 2-S which is available with the 3, 10, or 15 KVA option. The model 3-S is only available in the 3 KVA option. This model is ideal for infrequent use. If you are interested in our smallest tabletop, the 2-SE offers the same KVA options.
If you will need to disintegrate up to 5/8″ studs and bolts, you will want to go with the 10 KVA option for your AC metal disintegrator. The portable model 2-SQT offers you the option of 10, 15, or 20 KVA. The 2-SA series offers a larger tabletop size and the option of 10 or 15 KVA.
Power Supplies
3 KVA, 10 KVA, 15 KVA, 20 KVA
Larger-diameter holes require more power to maintain an effective arc.
3 KVA disintegrates taps up to 3/8″ in one single pass.
10 KVA disintegrates taps up to 3/4″ in one single pass.
15 KVA disintegrates taps up to 1-1/4″ in one single pass.
20 KVA designed for larger taps, drills, studs, and bolts.
Disintegrate up to 1 1/4″ taps and drills with a 15 KVA metal disintegrator.
Only choose the 20 KVA option if you will be disintegrating studs and bolts which are 1″ and larger.
Each machine is built to match your building power, you must specify 208, 240, 380, 480 or 550 at the time of order.
Choose a DC machine if you will be disintegrating carbide. The power input choices for a DC machine are 30 AMP 110-600. All Electro Arc metal disintegrators are single input voltage.
Machinists: Machinists use metal disintegrators to remove broken bolts, studs, and other components from machinery and other equipment. This is a popular service to offer customers considering the time commitment to remove a broken bolt or other tooling using traditional methods usually takes hours if not days and may further damage the part. Many customers try a product like “Easy-Out” and end up with an even bigger broken bolt problem when it doesn’t work.
Specialty Equipment Mechanics and technicians
Mechanics and shop techs use metal disintegrators to repair and maintain large equipment and off-road vehicles.
Applications range from removing broken taps and drills in engine blocks, heads, and power trains to removing broken tooling such as broken 10MM (3/8″) exhaust manifold studs which can be disintegrated in three and a half minutes.
You can use Electro Arc portable metal disintegrator units such as the Model 2-SQT to remove broken taps and bolts in hard-to-reach places or extremely large castings like the arms of bulldozers or radiator housings on the D10.
Industrial Maintenance
Maintenance Technicians: Maintenance technicians use metal disintegrators to quickly remove broken components from critical systems such as power plants, aerospace equipment, and military equipment.
Remove rusted bolts, remove large bolts quickly without damage to the machinery, and remove bent and frozen bolts in energy and oil industrial applications. Maintain power equipment with rapid repairs on power lines and wind turbines.
Use our model 2-SB to repair ships and submarines. This model is specially designed to fit through the circular bulkhead of a submarine or shop to perform maintenance. This machine can be built to run on water allowing you to use ths compact design for emergency repairs virtually anywhere on your craft.
Engineers: Engineers use metal disintegrators to perform research and development on new materials and components.
Gunsmiths: Gunsmiths use metal disintegrators to remove damaged or seized components from firearms.
Automotive Production and Repair
Maintaining costly equipment in automotive production is quicker if you have broken tooling causing a downed assembly line. Keep your equipment running at optimal uptimes with an Electro Arc metal disintegrator.
Automotive Technicians: Automotive technicians use metal disintegrators to remove broken bolts, studs, and other components from automotive components like alternators, engine blocks, starter bolts, and cylinder heads.
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.
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.
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:
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.
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!
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.
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.
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 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.
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 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.
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.
At Electro Arc we know that time is important to you. How often can you get things done faster without sacrificing quality? Not very often. You will find a different experience with Electro Arc’s metal disintegrators (spark eroders). We have been providing the world with the highest quality EDM portable and table top machines since 1947. We are celebrating 75 years of local metal disintegrator production.
SAVE TIME WHEN YOU USE AN ELECTRO ARC METAL DISINTEGRATOR– You can remove broken taps, drills, and bolts in seconds. This doesn’t have to be a long process using a cheap machine that may even not get the job done. Other technology can take up to hours to get done.
SAVE MONEY – When you use an Electro Arc metal disintegrator, you can return to normal operations fast! You will save money that could be lost on downtimes, and salvage expensive parts that can be destroyed using a cheap disintegrator or spark erosion machine, or due to the broken bolt, tap, or dowel. Scrap fewer parts and take advantage of quick problem-solving that lasts for years.
QUALITY – All of our machines are made to order, 50-65% of the parts are machined right here in our shop. Every machine is assembled and tested here in Dexter, Michigan. you can count on faster, more efficient, and the most cost-effective method to remove broken tools, studs, taps, bolts, drills or fasteners. These machines leave the hole intact which will minimize damage to expensive parts.
DURABILITY – Electro Arcs’ reputation precedes us. Our machines are built to last, we have customers using machines that are 40+ years old! Our machines stand up to the rough environment of shops, factories, production facilities, and outdoor use in mines, on off-road machinery, and in military applications.
SUPPORT – We have logs of every machine we have ever sold. If we made it, we repair it. We sell accessories including molybdenum electrodes (also made on-site) to support your machine.
We manufacture DC and AC machines. Our metal disintegrators work well with all hardened metals like High-Speed steel tooling. Our portable machines are versatile and ideal for use in many fields to quickly remove a broken tap, drill, or bolt and continue normal operations. Our DC machines are great for Carbides and soft cast metals.
