Crack Repair of Cast Iron by Metal Stitching/Metal Locking Process

RA Power Solutions Pvt. Ltd. has recently undertaken crack repair of cast iron engine block by metal stitching and metal locking process. Engine block which is made of cast iron was broken from the window cover sitting area. The engine block was broken in to pieces measuring approximate 330 x 420 mm.

RA Power Solutions Pvt. Ltd. after getting the dimensions got the casting made of cast iron and it was metal locked and metal stitched on board a vessel. The engine after repairs is performing satisfactory.

Broken Engine Block
Broken Engine Block
Cast Iron Casting Prepared by RA Power Solutions Pvt. Ltd.
Cast Iron Casting Prepared by RA Power Solutions Pvt. Ltd.

 

 

 

 

 

 

In 37 years of experience we have executed more than 1000 jobs of crack repair by metal stitching and metal lock surgery not only for shipping but for all sectors of industry.

Perhaps we are the only company in the world to execute crack repair of engine components or any crack in metal on board a vessel while sailing.

Metal stitching and metal locking process on board the vessel:

Keys and Locks Used in Metal Locking and Metal Stitching Process
Keys and Locks Used in Metal Locking and Metal Stitching Process
Metal Stitching Under Progress on Board the Vessel
Metal Stitching Under Progress on Board the Vessel

 

 

 

 

 

 

 

Metal Stitching Under Process
Metal Stitching Under Process
Casting Piece Stitched in Broken Area of Engine Block
Casting Piece Stitched in Broken Area of Engine Block
Metal Stitching and Metal Locking Under Progress
Metal Stitching and Metal Locking Under Progress

 

 

 

 

 

 

 

Final finish given to Damaged Area of Engine Block
Final finish given to Damaged Area of Engine Block

 

 

 

 

 

 

 

 

 

Author is Mr. Raj Shahani, Managing Director of the company. He is having 37 years of experience in metal stitching and metal locking of crack repair, grinding of crankshaft and all services related to repair of engines and supporting equipments.

Company has in-house trained technicians,equipments and serves all over the world.

Crack Repair by Metal Surgery

RA Power Solutions Pvt. Ltd. was called by a leading forging company based in western part of India manufacturing open forgings for heavy engineering plants. One of the operation involved use of clear space pneumatic hammer which they imported from massey of UK.

Due to constant use of forging hammer and its age the pneumatic chamber of the hammer developed a crack measuring 69 inches. The whole plant due to non operation of this critical equipment was on stand still. The pneumatic chamber is manufactured out of grey cast iron. The company tried to repair the crack by welding process and engaged a leading company to execute the repairs. The crack repair of the cast iron pneumatic chamber was not successful. RA Power Solutions Pvt. Ltd. was called to repair the crack by metal surgery process.

Materials Used in Metal Stitching/Metal Locking Process
                       Materials Used in Metal Stitching/Metal Locking Process

RA Power Solutions Pvt. Ltd. initially carried out magnetic particle test (MPI) and dye penetrant test of cast iron pneumatic chamber to check the exact length and the profile of the crack developed. The paint including red oxide applied on the cast iron pneumatic chamber was removed completely. The crack of 69 inches was repaired by our technicians by metal stitching and metal locking process.

The keys, master metal locks and all consumables used for metal surgery were imported from UK. After the completion of metal stitching and metal locking operations, the chemicals were applied to stop the air leakage from the pneumatic chamber.

Metal Stitching/Metal Locking Procedure
                                 Metal Stitching/Metal Locking Procedure

This process of metal surgery followed by us for repair of crack in cast iron is cold process, no heat is generated and is proven method for successful repair of crack in cast iron casting.

We have more than 37 years of experience of executing crack repair in cast iron by metal surgery and have experienced technicians available to execute the crack repair onsite in minimum time and cost.

Crack Repair by Metal Surgery
                            Crack Repair by Metal Surgery

 

Metal Locking and Metal Stitching of Engine Block on Board the Vessel

A vessel sailing in Middle East reported damage of engine block of Yanmar 6N21L-SN due to accident.

Yanmar Marine Diesel Engine
Yanmar Marine Diesel Engine

RA Power Solutions Pvt. Ltd. deputed team of technicians with consumables. The broken pieces were assembled and metal stitched/metal locked. Total broken area was 46 inches. The broken pieces were re-assembled and metal stitched due to shortage of time and to put on the generator in minimum possible time. The other alternate option  was to use the new piece of casting which was not done in this case due to shortage of time.

Broken Engine Block of Yanmar Engine
Broken Engine Block of Yanmar Engine
Assembly of Broken Pieces of Engine Block
Assembly of Broken Pieces of Engine Block

 

 

 

 

 

 

Metal Stitching of Engine Block in Process
Metal Stitching of Engine Block in Process
Metal Locking of Engine Block in Process
Metal Locking of Engine Block in Process
Repair of Engine Block by Metal Locking Process
Repair of Engine Block by Metal Locking Process
Engine Block Ready After Metal Stitching Process
Engine Block Ready After Metal Stitching Process

Metal Stitching of Crack Casting

Cast iron components develop cracks and break into pieces as a result of accident or overload. The replacement of crack component is expensive. It is recommended to repair crack and broken casting by metal stitching/metal locking process.

Repair Crack and Broken Casting by Metal Stitching Process
       Repair Crack and Broken Casting by Metal Stitching / Metal Locking Process

RA Power Solutions undertakes repair of crack engine block, cylinder heads and cast components onsite by metal stitching and metal locking process which is proved to be successful.

Repair of crack components  is executed by experienced technicians and we use the consumables comprising of metal locks and metal keys procured from companies based in UK and USA. We also stand guarantee for the satisfactory performance after metal stitching/metal locking of the component. Most of the metals can be metal stitched where repair of crack  by welding is not successful.

Metal Stitching of Jenbacher Engine Block
Metal Stitching of Jenbacher Engine Block

 

Metal Stitching Done in Broken Area of Generator
Metal Stitching Done in Broken Area of Generator

Metal Locking of Steel Casting

RA Power Solutions undertakes onsite repair of engine block, compressor and rotary equipment for last more than 36 years. We feel that the repair of crack developed in cast iron, steel castings are repaired successfully by metal locking and metal stitching process without losing the original profile.

Insertion of Casting Piece into Engine Block Area
Insertion of Casting Piece into Engine Block Area
Metal Locking Under Process
Metal Locking Under Process

 

 

 

 

 

 

 

 

RA Power Solutions has executed successfully more than 600 jobs for the repair of housings which are damaged due to development of crack or casting is broken into pieces. The advantage of metal locking and metal stitching is that in case large area of casting is damaged a new piece having similar metallurgical properties is cast and metal stitched on the parent body of the casting.

Metal Stitching/Metal Locking of Jenbacher Engine Block Under Process
Metal Stitching/Metal Locking of Jenbacher Engine Block Under Process

Recently, we have undertaken repair of Jenbacher engine block. The casting of engine block i.e lower crankcase was broken into pieces, a new piece measuring 10 X 12 inch was metal stitched successfully.

We use proven and high quality of metal keys and metal locks and stand guarantee for the performance

 

Metal Stitching of Jenbacher Engine Block
Metal Stitching of Jenbacher Engine Block
Engine Block After Completing Metal Locking Process
Engine Block After Completing Metal Locking Process

 

 

 

 

 

 

 

 

Author of this blog is Raj Shahani, Managing Director of RA Power Solutions Pvt. Ltd. having experience of more than 36 years. He is instrumental in executing successfully repairs of crankshaft, engine block, cylinder heads, connecting rods and mechanical equipments replacement cost of which works out in millions of dollars. The reputed companies spread all over the world regularly benefit from the rich experience of RA Power Solutions having excellent latest infrastructure required for repairs.

You can email us on rajshahani@rapowersolutions.com or Call us on +91-9810012383