The repair of crack and repair of damaged casting by welding process is now completely outdated and is not recommended for repair of damaged cast metal and cast iron parts. In fact, it is observed that in certain cases repair by welding results in more serious damage due to the generation of heat and stress during the process of welding. RA Power Solutions have been undertaking repairs of the damaged engine block, steel components repair, cast iron repairs and all types of cast components by metal stitching and metal locking process for last four decades.
We have a separate and dedicated team of technicians who have the capability to undertake the onsite repair of crack and damage casting by using portable tools and high-quality consumables (locks and keys ) which are imported by us from UK.
I) It is possible to undertake crack repair and repair of damage casting by metal stitching and metal locking process onsite. Hence there is no requirement of transporting the crack or damage components to the workshop.
II) In most of the cases, there is no requirement of dis assembly of equipment.
III) We possess portable tools to execute the repairs on site.
IV) The time duration for repair of crack and damaged cast components by metal lock and metal stitching is low.
V) Metal Stitching and Metal Locking is a permanent crack repair method as no heat is generated which is associated with welding.
VI) The crack and damaged area after repair by metal locking and metal stitching process are restored to its original profile and are also recommended for gas or watertight repair.
VII) Repairs are undertaken with the guarantee.
The repair by metal stitching and metal locking process can be undertaken of cast iron, aluminum parts including the following :
I) Damaged turbocharger casing.
II) Pump casing and gearboxes.
III) Cracked engine block, cam covers, cylinder liners, turbine casings, and all components.
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.
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.
RA Power Solutions was recently approached by a diesel power plant based in South America having Wartsila 12V32 and Wartsila 18V32 diesel generating sets.
A serious accident took place due to failure of cylinder liner resulting in to the damage of various parts including lower and upper engine block of Wartsila 18V32 engine. On investigation by RA Power Solutions technicians it was observed that upper and lower engine block suffered severe multiple cracks measuring to total 2900 mm in length and damage of casting into small pieces measuring 300 X 460 mm.
Various options were discussed and it was decided to replace the lower and upper crankcase. The cost of replacement of damage lower and upper engine block of Wartsila 18V 32 was exorbitant with a delivery period of 9 months. RA Power Solutions proposed to repair the multiple cracks and damaged portion by metal stitching and metal locking process. This is a cold process of crack repair and has been followed by our technicians in number of installations all over the world during our service to the industry for last four decades
The damaged portion of the engine block was given a discipline profile and new piece of casting having similar metallurgical properties as of the parent material was placed and metal stitched using the latest design of metal stitching locks and keys. The multiple cracks were properly marked by our technicians using the latest MPI equipment to identify the cracks. The multiple cracks were also repaired by metal stitching and metal locking process.
RA Power Solutions also undertook the onsite grinding of crankshaft which got damaged due to accident and re-assembled the engine in 16 days time. All these repairs were conducted in-house with the onsite portable equipments which were carried to the site by the technicians. Perhaps no other company in the world can offer all repair services under the same roof.
The engine is performing satisfactory.
RA Power Solutions specializes in cast iron repairs, utilizes advance metal stitching and metal locking processes that are ideal and most suited for this type of crack repair.
RA Power Solutions takes the pride to announce that in our four decades of experience, we were able to save millions of dollars of end users by undertaking the onsite repairs of damaged parts avoiding the expenses towards the cost of new parts which are exorbitantly priced with long delivery.
We have a dedicated team to undertake the repair of crack and damaged engine components. It is possible to undertake metal stitching and metal locking for repairs of crack on a moving vessel.
Technicians can join the vessel in short time as they carry seaman passport. As an Indian company we are respected for our sincerity, experience and lowest cost.
Repair of cracks developed in commonly used industrial castings and metal is possible to repair by cold method called lock and stitch. It is also known as metal stitching and metal locking. In case of cast iron equipments and parts damaged in to pieces.
RA Power Solutions Pvt. Ltd. undertakes repair by lock and stitch process which is cold method as no heat is generated. Crack repair by lock and stitch method in cast iron is proved to be of great success in comparison to the crack repair by welding.
In case of critical cast iron components like engine block, main journal housings, cylinder heads, turbine casings crack repair by metal stitching is highly recommended as it does not develop any misalignment of the casting or shrinkage. We undertake crack repair of cast iron for last more than 37 years on time, within budget and with experienced technicians.
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.
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.
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.
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.
In case of crack developed in casting of mechanical equipments the repair of metal stitching and metal locking is proved to be the best and successful process. In case of engine block and turbine casings, heavy castings is used in mechanical equipments. It is quite difficult to replace them due to cost, time factor and interchangeability issue.
The repair of cracks by metal stitching and metal locking is a cold process. No heat is generated and the same original profile is maintained. In case of cracks developed in housing of engine block, the crack repaired by metal locking and metal stitching is highly recommended as there is no distortion in the central line of the housing takes place.
RA Power Solutions have experienced technicians to undertake metal stitching and metal locking process with guarantee.