There is no need of replacement of major components of engine or the equipment installed in heavy engineering plants in case of development of crack or damage of casting. It is possible to undertake onsite repair of crack and damaged component irrespective of its application and profile by metal stitching and metal locking process.
JIBB PLATE OF 225 TON
BROKEN AREA
REPAIR BY METAL STITCHING PROCESS
Finished by RA Power Solutions, India
The main features of undertaking crack repair and repair of damaged casting of engine block and heavy cast components by metal locking are as follows:
It is possible to replace the large portion of damaged components by using new casting piece, this is done by metal stitching and metal locking process.
Metal Stitching of Engine Block in Process
Metal stitching and metal locking is the most trusted technology of crack repair as no heat is generated. It is a cold process and there is no change in the shape and profile of the component unlike in the welding process.
Repair of crack by metal stitching and metal locking is possible onsite without disassembly of the equipment.
The crack repair and repair of damaged casting by lock and stitch method is far more cost-effective than the purchase of expensive and new parts.
Only company providing crack repair services on board the vessel while it is sailing. All repairs undertaken are guaranteed by RA Power Solutions engineers. A company with four decades of experience.
Metal Stitching and Metal Locking Under Progress
Engine Block Ready After Metal Locking Process
To know more about metal stitching, engine cylinder liner, metal stitching engine block, cold stitching cast iron, cold stitching engine blocks, metal surgery, and cast iron crack repair, Contact us at rajshahani@rapowersolutions.com or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383 for more information.
RA Power Solutions Pvt. Ltd. extends repair services for main and auxiliary engines, high-capacity compressors, pumps, and rotating equipment. We have the latest design portable equipment which is carried to the client’s site, whether they are land-based power plants or vessels on the move. The services are offered through trained technicians. Being an Indian company having more than 36 years of experience, we are well known for sincerity, on-time services, and the lowest price in this industry. A few of the services offered to us are as under:
Metal Locking and Metal Stitching
Metal locking and metal stitching is a cold process for repair of steel casting which develops cracks or gets broken into pieces due to overload, stress, or an accident. RA Power Solutions Pvt. Ltd. has experience of more than 44 years of undertaking repair of most complex accidental damage to plant and machinery, high capacity marine engines, diesel generating sets, engine blocks, cylinder heads, turbine casing, etc. The repair of casting by metal stitching and metal locking has been executed by trained and experienced engineers having experience of 44 years.
Broken Engine Block of Yanmar Engine
Assembly of Broken Pieces of Engine Block
Engine Block Ready After Metal Stitching Process
Engine Block Ready After Metal Locking Process
Consumables like metal locks and metal keys are procured from reputed companies based in the USA and UK. We are cost-effective and can depute our team of technicians within 6 hours notice.
Material Used in Metal Locking and Metal Stitching Process
We are experts in the repair of crankshafts of high-capacity marine engines up to 700 mm diameter, diesel generating sets, and other applications. The services are extended all over the world through our experienced technicians.
Rotor Shaft Grinding
In case of failure of the white metal rotor shaft bearing, it is necessary to inspect the rotor shaft bearing sitting diameter. We undertake complete inspection of the rotor shaft, grinding and polishing onsite. The rotor shaft repair, grinding, and polishing are done without dismantling the rotor shaft from the casing. The rotor shaft grinding and polishing are done onsite.
Rotor shaft white metal Babbitt bearings are manufactured and rebabbitting of old rotor shaft bearings is also undertaken. We guarantee the satisfactory performance of white metal Babbitt bearings.
Onsite Rotor Shaft Grinding
Rotor Shaft Grinding in Process
Connecting Rod Repair
Connecting rod repair is undertaken with a guarantee, absolutely no need to replace the connecting rod as in most cases connecting rods can be repaired and re-used.
RA Power Solutions Pvt. Ltd. undertakes in-house repair of connecting rods including re-boring of the big ends and small ends, checking for hardness, cracks, etc.
Connecting Rod Assembled with Piston After Repair
Liner, Piston, Connecting Rod, and Cylinder Head Under Assembly Supplied by RA Power Solutions
Connecting rods for all make and models of diesel engines like MAN-B&W, Sulzer, Wartsila, MAK, Deutz, Pielstick, Mitsubishi, Daihatsu, Yanmar, Bergen, Niigata, Himsen, Allen, Stork, Fiat, MWM, Hanshin, Caterpillar, SKL, Ruston, Paxman, Crepelle, Mirrlees, Alco, ABC, Nohab, etc.
Connecting Rod of MAN engine
Reconditioning of Connecting Rod
Cylinder Heads
Cylinder Heads are reconditioned at our works. We replace valve seats, and valve guides and recondition the cylinder heads which are ready for installation. Repair of cylinder heads is undertaken by our experienced technicians in-house.
The repair of cracks on cylinder heads is done by metal stitching and a metal locking process, which is a cold and proven method of crack repair. Second-hand reconditioned cylinder heads are also supplied with a guarantee at a competitive price.
Cylinder Head of Marine Diesel Engine
Cylinder Head
Rebabbitting of Bearings
Rebabbitting of old white metal bearings of diesel engines, turbines, alternators, and all applications are undertaken. Rebabbitting of white metal bearings is done by a centrifugal process, which ensures dense and uniform bonding with the base steel.
We undertake rebabbitting of bearings up to 1500 mm in diameter. The white metal used for rebabbitting is imported from Spain. The metallurgical certificate for white metal and dimensional inspection report is submitted after rebabbitting of white metal is done. For more information on onsite crankshaft repair services, cylinder liners exporter, cylinder liners, engine cylinder liner, cylinder sleeve manufacturer, metal locking, repair of rotor shaft, and onsite repair services of crankshaft contact us at rajshahani@rapowersolutions.com or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.
A vessel sailing in the Middle East reported damage of engine block of Yanmar 6N21L-SN due to RA Power Solutions Pvt. Ltd. deputed a team of technicians with consumables. The broken pieces were assembled and metal stitching and metal locked. The total broken area was 46 inches. The broken pieces were re-assembled and metal stitching was due to a shortage of time and to put on the generator in the minimum possible time. The other alternate option was to use the new piece of casting, which was not done in this case due to a shortage of time accident.
Yanmar Marine Diesel Engine
RA Power Solutions Pvt. Ltd. deputed a team of technicians with consumables. The broken pieces were assembled and metal stitched/metal locked. The total broken area was 46 inches. The broken pieces were reassembled and metal stitched due to a shortage of time and to put on the generator in the minimum possible time. The other alternate option was to use the new piece of casting, which was not done in this case due to a shortage of time.
Broken Engine Block of Yanmar Engine
Assembly of Broken Pieces of Engine Block
Metal Stitching of Engine Block in Process
Metal Locking of Engine Block in Process
Repair of Engine Block by Metal Locking Process
Engine Block Ready After Metal Locking Process
For further details regarding the metal stitching of engine block, metal stitching service provider, broken engine block of Yanmar, Yanmar marine diesel engine, and broken engine block, etc. contact us at rajshahani@rapowersolutions.com or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.
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 and metal locking process.
Repair Crack and Broken Casting by Metal Stitching / Metal Locking Process
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. To get more information regarding cracked engine block metal stitching, metal stitching for repair of cracks contact us at rajshahani@rapowersolutions.com or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.
RA Power Solutions has undertaken onsite repair of engine blocks, compressors, and rotary equipment for the last 44 years. We feel that the repair crack developed in cast iron, and 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
Metal Locking Under Process
RA Power Solutions has executed successfully more than 600 jobs for the repair of housings that are damaged due to the development of cracks or casting broken into pieces. The advantage of metal locking and metal stitching is that in case a 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
Recently, we have undertaken repair of the Jenbacher engine block. The casting of the engine block i.e. lower crankcase was broken into pieces, and a new piece measuring 10 × 12 inches was metal stitched successfully. We use proven and high-quality metal keys and metal locks and stand guarantee for the performance.
Metal Stitching of Jenbacher Engine Block
Engine Block After Completing Metal Locking Process
The author of this blog is Raj Shahani, Managing Director of RA Power Solutions Pvt. Ltd. having experience of more than 44 years. He is instrumental in executing the successful repair of crankshaft, engine block, cylinder heads, connecting rods, and mechanical equipment replacement costs which works out to millions of dollars. The reputed companies spread all over the world regularly benefit from the rich experience of RA Power Solutions having the excellent latest infrastructure required for repairs.
To know more about the repair of cracks in cast iron casting, repair cast iron, cast iron repair, metal stitching service provider, metal locking, and cast iron crack repair email us at rajshahani@rapowersolutions.com or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.
