Cast Iron Crack Repair By Metal Stitching

Steam turbine casing of Hangzhou make was reported damaged due to accident. The turbine operates at 130 MW peak load.

RA Power solutions deputed technician to the site with latest breed of instruments, equipments and consumables in order to undertake inspection of the turbine casing and to execute necessary repair following observation was made.

Observation-

Turbine casing due to accident developed multiple cracks at different locations. Crack of following dimensions were observed

  • Crack having a length of 190mm with indiscipline profile

  • 2 Cracks having length of about 300mm

  • Casting having dimensions of 600mm/450mm with thickness of 45mm was damaged into pieces

Crack repair by Metal lock and Metal stitching.

Crack Repair and damaged casting replacement was under taken by RA power technicians.

    • The damaged casting area was cut and disciplined profile was given measuring 650mm/520mm this area was properly ground

    • The damaged sample piece was sent for metallurgical test to know the composition of material.

  • A wooden pattern was made at site having an exact profile as of damaged area

    • A new casting piece having superior metallurgical properties then the original damage casting was manufactured

  • The new casting piece was fixed in damage area by metal stitching and metal locking process

    • RA power engineers used metal locks, metal keys and all consumables’ imported from UK for repair of cracks and damage casting

  • The polishing of outer and inner surface of damaged area was done and painted

  • The turbine is presently working satisfactory and has completed 3500hr of operation.

RA power under takes repair of crack casting by metal stitching and metal locking process from last 40 years and have executed successfully repair of heavy components used in power plants, industry, ships etc…

The metal stitching and metal locking can also be undertaken while sailing of the vessel.

Turbine casing
Turbine Casing
Damaged turbine casing
Damaged turbine casing
Turbine casing after repairs
Repair of casing by metal lock and metal stitching
Turbine casing after repairs
Turbine casing after repair

Lock and Stitch Cast Iron Repair

Heavy castings like turbine casing, gearboxes, engine block, heads and heavy cast iron parts  need not to be disassembled in case of development of crack in casting or breakage of casting in to pieces due to accident.

Cold metal stitching and metal locking process is used to repair cracks in cast iron. The process of crack repair by metal stitching and metal locking does not require any welding and generation of heat. The time has proved that the crack repaired in casting by metal stitching and metal locking is far stronger and more durable in comparison to the repair of crack by welding process.

Repair of Broken Casting by Metal Stitching Process
Repair of Broken Casting by Metal Stitching Process
Broken Engine Block of Yanmar Engine
Broken Engine Block of Yanmar Engine

In most of the cases crack repair in casting is possible onsite and there is no need of transporting the heavy cast piece to the workshop. RA Power Solutions Pvt. Ltd. undertakes crack repair by metal stitching and metal locking process for last more than 3 decades and have executed number of repairs successfully all over the world.

RA Power Solutions Pvt. Ltd. is the first company which can undertake repair of high capacity engine blocks, turbine casings, cylinder heads and all cast parts installed on the vessel while it is on move.

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

 

 

 

 

 

 

 

The lock and stitch cast iron repair executed by us is guaranteed for satisfactory performance. We are cost effective and priced lowest in the industry.

Metal Stitching and Metal Locking of Engine Block
Metal Stitching and Metal Locking of Engine Block
Engine Block After Repair
Engine Block After Repair

Metal Stitching and Metal Locking of Engine Block

Engine blocks, casting and most of the parts are manufactured of common material like cast iron. Cracks developed in cast iron parts are most difficult to undertake repair by welding process as it needs pre-heating of the cast iron prior to the welding. In certain cases it can cost additional stresses resulting to the damage of casting.

Material Used in Metal Locking and Metal Stitching Process
                                  Material Used in Metal Locking and Metal Stitching Process

It is proven that metal stitching and metal locking has advantage of repairing cracks in cast iron casting due to cold process using different profile and material of stitching pins and locks without applying any heat as in case of welding.

RA Power Solutions Pvt. Ltd. undertakes metal stitching and metal locking of casting and has successfully repaired various major components of high capacity diesel engine.

Application includes repair of Engine Block, Cylinder Head, Generators. Turbo Chargers, Turbine Casing, Gear Box Housing,     Pump Casings, Compressor Crank Cases ,Forgings Hammer, Lathe / Press/ Milling/Boaring etc .M/c. Other all Casting Equipments etc. 

In last 36 years more then 650 jobs of crack repair have been successfuly   executed.

Stitching Pin Used in Metal Stitching Process
Stitching Pin Used in Metal Stitching Process
Metal Stitching Done in Broken Area of Generator
             Metal Stitching Done in Broken Area of Generator