The birth of Metal Disintegrators by Electro Arc

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As Stillion Industries and Electro Arc celebrate dual anniversaries, a lot of research has exposed historic information about our Electro Arc line of metal disintegrators and the company. An accidental discovery of carbide impregnation through EDM had been untapped in the metalworking industry despite the discovery in the 1940s because it was such a new process operator error was leading to problems. Electro Arc was one of the pioneering companies that changed the market by developing their line of Metal disintegrators.  Through the use of carbide impregnation, great success was found with use on hard metals such as drills, lathe turning tools, and taps. In July of 1971, Electro Arc’s carbide-impregnating machine was mentioned by the Machinery magazine discussing the promise of carbide impregnation.  The article mentions Spalding using the Electro Arc model F-5 machine to impregnate dies and punches extending the life of their tools considerably.  It also mentions a California manufacturer who recovered the cost of their machine in just two months by extending their drill life by 10 times. Electro Arc Carbide impregnation throwback (above) Since then Electro Arc discontinued machines like the F-5 in favor of the Metal disintegration line their reputation in the industry is long-lasting.  As the original maker of metal disintegrators, machines like the Electro Arc Model HK6VQT continue to offer the largest table model machine and heavy-duty superstructure available with heavy-duty power, and auto-feed for the fastest cutting disintegrator with increased machine operator productivity.  With innovation and efficiency, the line of metal disintegrators has grown to include over 40 models with an option to custom-build your machine and lots of accessory choices. Electro Arc Model HK 6VQT Metal Disintegrator This Electro Arc disintegrator will pierce any material that will conduct electricity and produce holes of any shape from .010 and larger.  The Electro Arc patented metal disintegrator design features maximum disintegrating power for the highest cutting speed.  No special skill is required to operate the metal disintegrators.  These built-to-last machines are still serving customers from over 50 years ago! See an Introduction to Electro Arc Portable Metal Disintegrators Below:

What are the Challenges of Manufacturing and Stocking your Own Parts?

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Stillion Industries has been machining parts in Southeast Michigan since 1972.  To meet increased demand from regular customers we have purchased new machines in the past few years.  These new machines have helped us increase our capabilities and efficiency.  Stillion Industries’ operations have moved a few times over the years.  Most recently, the expansion of our location occurred in 2014. Stillion Industries’ property consists of 5 buildings with one building dedicated to machining, one dedicated to building Electro Arc machines and testers, and another one dedicated to producing Molybdenum electrodes. We purchased Electro Arc in 2019, increasing our internal demand for machined parts.  Electro Arc used Stillion Industries as a vendor for years. So we are familiar with many of the new parts we make for the Electro Arc product lines. The metal disintegrator machines are composed of hundreds of parts. We now machine about 60% of the parts needed for those machines in-house. Our Ames testers are 97% machined in-house. We have been able to improve our manufacturing process for these parts over the past 3 years. As with any major change, the process of integrating Electro Arc operations into the existing Stillion Industries location was tricky. Electro Arc had been in business for 72 years when we acquired it. The number of items that needed to be integrated into our operations was significant. Integrating new staff and staff roles into the machine shop changed our operations completely. Going from offering services to offering products and services required new software, training, and coordination while maintaining existing operations. Three years later, we continue to improve our systems and manufacturing processes. A Look Inside Stillion Industries https://youtu.be/PsykXjx33PM Our main challenge in stocking our own parts has been balancing internal work with outside work. Supply chain issues have also created scheduling delays.  In many cases, we must wait for other jobs to finish in order to complete a job for our metal disintegrators or Ames testers.  Since each tool and machine is custom-made, our turnaround time can be delayed due to a lack of parts. Obviously, this is less than satisfactory for our customers who are also waiting for our products which require parts and products both from our own machine shop and outside sources. While we can stock our Ames hardness testers ahead of time, we have not been able to stock the metal disintegrators as a shelf-ready item to order.  The investment per machine is significant and since we offer over 40 different models, with  custom options for building power, we cannot pre-fabricate these machines.  Changes in the economy have affected our buyer behavior and we haven’t been able to anticipate the volume of new orders.  We have also explored offering refurbished metal disintegrators for sale.  This is advantageous for customers who would not normally be able to afford a new machine. We offer machine refurbishing services for machine owners as well.  Our first refurbished machine was in new condition and was sold with a 1-year warranty. Used machines found on the market through avenues like Ebay won’t offer this benefit.  Electro Arc had elected not to offer refurbished machines in the past.  Stillion Industries is exploring the possibility of offering refurbished metal disintegrators regularly. As an additional option, we are considering offering a buy-back program for owners of metal disintegrators who would otherwise sell their machines through third-party machine sellers.  This way, the machines can be factory certified and we can continue to offer used machines for sale. All Parts Manufactured by Stillion Industeries are Made in Michigan Shop Ames and Electro Arc Products online: All Ames Ames, Superficial Portable Rockwell Testers Ames Model 4-2S Portable Hardness Tester ☆☆☆☆☆$3,916.47Add to Cart Ames, Test Blocks Ames Superficial Brass Test Block ☆☆☆☆☆$188.38Add to Cart Ames, Standard Portable Rockwell Testers Model 8 Ames Portable Hardness Tester ☆☆☆☆☆Add to Cart Load More End of Content. All Electro Arc Collet, Electro Arc, Electro Arc Accessories Collet .118 ☆☆☆☆☆$58.56Add to Cart Electro Arc, Electro Arc Accessories, Molybdenum Electrode Molybdenum Electrode 0.375-S ☆☆☆☆☆Add to Cart Electro Arc, Electro Arc Accessories, Molybdenum Electrode Molybdenum Electrode 0.020 ☆☆☆☆☆Add to Cart Load More End of Content.

Stillion Industries services Model F-5 Carbide Impregnators

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Die-hard Electro Arc fans remember the Model F-5 Carbide impregnator, like the Cherry Rivet Division which found the F-5 extended the life between sharpenings on their drills by a factor of ten as mentioned in The Machinery article “Carbide impregnation – stepchild process with tremendous potential” published July 1971.  Spaulding Fibre company was also quoted stating they were able to produce 2-4 times the parts between sharpenings when they used the Electro arc Model F-5 to impregnate their dies and punches.   A snippet from the original publication “Carbide Impregnation – The stepchild process with Tremendous Potential” In a separate article also published by Machinery, “Broaching encroaching on milling” Mercury Broach states they use the Electro Arc Carbide impregnator daily.  They were able to improve the life of their high-speed broach 2-4 times between sharpening and process materials normally considered marginal for high-speed steel broaches. In response to these publications, Electro Arc released two Engineering bulletins.  An Indiana company Speedgrip Chuck had determined that carbide impregnation improved the life of their collets and chucks substantially.  In response to the success they had achieved, they received increasing requests from their customers for carbide impregnation.  In turn, these customers became customers of Electro Arc, purchasing their own machines. Similarly, a company based in Utica NY Kelsey-Hayes a company manufacturing buckets or fins that fit jet engine turbines, which due to the inspection requirements for precise forging had to be remade on an average of 3 weeks.  When impregnating their blades they found the life was increased to an average of four months! The same principles that inspired the innovation offered by the Electro Arc carbide impregnator, lent themselves to each of Electro Arc’s metal disintegrating machines.  These long-lasting machines continue to improve the life of parts, reduce cost and increase efficiency for our customers.  When you have a large, heavy part the cost of replacing the entire piece like a wind turbine or jet engine is inconceivable!  Electro Arc’s Metal disintegrators are made in different powers, sizes and are fully customizable to match the needs of your operations! While Electro Arc is no longer producing new F-5 machines, Stillion Industries continues to offer repair service and refurbishing of all Electro Arc products including the carbide impregnator.  Please do not hesitate to reach out to our sales team regarding any needs you may have regarding your Electro Arc machine!  Thank you for being a loyal Electro Arc customer and supporting Stillion Industries as we carry on this legacy.

Your Guide to Hardness Testing Accuracy

Ames Hardness Testers, , ,

Ames-certified test blocks assure accuracy with your Ames portable hardness tester every time.  Even if you are not using your hardness tester regularly, it still needs to be checked for accuracy.  The accuracy of Ames hardness testers is certified when you use Ames test specimens.  All Ames test specimens are traceable to national standards.   If You are Not Sure Which Test Block to Use for Accuracy Testing, Check out the Video Below: https://youtu.be/2GYJDSFyPLQ?si=_8az7llDEfuSNNUt You can check your tester’s accuracy by running a test on specimens of certified hardness using the following instructions. How to check your Ames Hardness Tester’s accuracy in 6 Easy Steps: Step 1: Select the penetrator and test block. Soft materials are usually tested in the Rockwell B Scale, using 1/16″ ball penetrator and 100 Kg Major Load. Hardened steel and hard alloys are tested in the Rockwell C Scale, using a diamond penetrator and a 150 Kg Major Load. *Do not use the ball penetrator with the steel test block or when testing hard steel. Such a procedure will damage the penetrator and result in invalid tests. Step 2: Set up the tester. Secure the penetrator and the appropriate anvil in the tester. Check the position of the indicator hand. It should rest directly on the dot on the indicator dial. If it doesn’t, adjust the dial by turning the bezel to locate the dot under the pointer. Step 3: Apply Minor Load. Slowly turn the hand wheel to bring the indicator hand to the line marked “SET”. This applies minor pressure load to the penetrator. Step 4: Set the Barrel Dial. Rotate the top of the barrel dial toward you until its pin rests against the upper edge of the Lucite magnifier. The upper line of the barrel’s hardness scales should be exactly aligned beneath the hairline on the magnifier. (NOTE: There is no pin on Model 1-4). These must be aligned visually.) Step 5. Apply Major Load. Turn the hand wheel only until the dial pointer rests on the major pressure load indicated by the chart. *Be careful to bring the indicator hand exactly to the desired graduation on the dial and no farther. (Once penetration goes beyond the major load, a valid reading can no longer be obtained from that penetration. Go back to Step 2. If reading can no longer be obtained from that penetration. Go back to Step 2. If you did not stop at the major load, then go on to Step 6.) Step 6. Take the reading! Turn the hand wheel back to bring the indicator hand back to “SET” and take the reading on the barrel dial through the Lucite magnifier. Each graduation on the barrel dial indicates two points in the Rockwell scale. Standard Tester: With the diamond penetrator, read Column C on the barrel dial (black numbers). With the ball penetrator, read column B (red numbers). Superficial Tester: With either the diamond or ball penetrator, take your reading from the black-numbered N-T column on the barrel dial. (The difference n reading is created by the difference in penetrators: N with diamond, T with 1/16″ ball.) NOTE: The first two or three tests may be low until the penetrator and anvil have become firmly seated. Remember, we recommend that you have your Ames hardness tester factory re-calibrated once a year to maintain accuracy and ensure a long life for your instrument.

We’re celebrating dual anniversaries in 2022!

1 CommentStillion Industries, , , , ,

Stillion Industries is 50 this year, and Electro Arc is 75 years Stillion Industries Stillion Industries started as a partner business, and was taken over by Chuck Stillion in 1972, he ran the business on Dino Drive in Ann Arbor until his son purchased the business from him in 2006. Electro Arc Electro Arc was started in Detroit Michigan in 1947, it moved to Ann Arbor about a year later and stayed there until it was purchased by Keith Stillion in 2019.  Chelsea Standard Newspaper Mention In the community In August 1989, Stillion Industries is mentioned as one of the local companies that contributed to Chelsea Fire Department’s Ladder 1 contributors. Stillion Industries listed in 1991 Palmer mentions Stillion Industries as one of the qualifying companies for an employee discount Stillion Employee in Community Project: Employee Chuck Waterbury is mentioned helping with a local project in connection with Stillion Industries Michigan-based, Michigan-made: Both Stillion Industries and Electro Arc started as and continued to operate as Michigan businesses. Stillion Industries celebrates 50 years Continuing the same great local service in the community, Stillion Industries is 50 years old in 2022! Electro Arc celebrates 75 years 75 years of Michigan-made high-quality metal disintegrators is a huge milestone for Electro Arc and Stillion!