Cast Iron Repairs | Cracked Engine Block Repair | Damaged Engine Bedplate Repairs | Metal Stitching – RA Power Solutions

The repair of a damaged engine block, turbocharger casing, heavy cast iron parts can be successfully repaired by metal stitching, metal locking, and metal surgery process.

The repair of crack and repair of damaged casting by welding process is now completely outdated and is not recommended for repair of damaged cast metal and cast iron parts.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.

Metal Stitching & Metal Locking of Suction Bell Mouth of CW Pump Repairing
Metal Stitching & Metal Locking of Suction Bell Mouth of CW Pump Repairing
Broken Suction Bell Mouth of CW Pump
Broken Suction Bell Mouth of CW Pump

 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.
Broken Area of Engine Block
Broken Area of Engine Block

 

Engine Block After Metal Stitching and Metal Locking
Engine Block After Metal Stitching and Metal Locking

 

 

 

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.

Metal Surgery under Process while Vessel is Sailing
Metal Surgery under Process while Vessel is Sailing
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.
IV) Heavy industrial and mining equipment.

For detailed repair process of damaged casting by metal locking and metal stitching, email us on info@rapowersolutions.com

Cast Iron Crack Repair By Metal Stitching – RA Power Solutions

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

Repair of Damaged Engine Block – RA Power Solutions

RA Power Solutions was recently approached by a diesel power plant based in South America having Wartsila 12V32 and Wartsila 18V32 diesel generating sets.

Broken Engine Block of Wartsila Diesel Engine
Broken Engine Block of Wartsila Diesel Engine

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.

Casting Piece Given Profile as per Damaged Engine Block
Casting Piece Given Profile as per Damaged Engine Block

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

Special Metal Locks and Keys Used in Metal Stitching Process
Special Metal Locks and Keys Used in Metal Stitching Process

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.

Special Keys Used in Metal Stitching
Special Keys Used in Metal Stitching

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.

Meta Stitching Of Engine Block is in Process
Metal Stitching Of Engine Block is in Process

 

Repair of Damaged Engine Block by RA Power Technician
Repair of Damaged Engine Block by RA Power Technician

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.

Repair of Engine Block by Metal Stitching/Metal Locking
Repair of Engine Block by Metal Stitching/Metal Locking While Vessel is Sailing

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.

For more information, please email us on info@rapowersolutions.com

Lock and Stitch Cast Iron Repair by RA Power Solutions Pvt. Ltd.

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.

Crack Repair by Lock and Stitch Method
Crack Repair by Lock and Stitch Method

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.

Cast iron repair by metal stitching and metal locking process have following main advantages

I) Repair of broken casting or crack developed in casting irrespective of its length is possible on site without dismantling the equipment.

II) Saves replacement of parts or equipments in totality and reduces downtime.

III) Cast iron repair by metal stitching and metal locking is the only process which restores strength in cast iron beyond the original casting.

IV) Metal stitching and metal locking is the only method known to be successful in replacing of the large pieces of broken casting with new piece.

V) Metal stitching and metal locking is the process which caters to heavy industry.

RA Power Solutions Pvt. Ltd. is the only company which can undertake crack repair by Lock and stitch method while vessel is sailing.

Complete Piece Replaced by New Casting
Complete Piece Replaced by New Casting
Engine Block of MAN Diesel Engine Broken Ito Pieces
Engine Block of MAN Diesel Engine Broken Ito Pieces

 

Metal Stitching of Forging Press - Crack Measuring 230 inches
Metal Stitching of Forging Press – Crack Measuring 230 inches
Repair of Engine Block of Yanmar Engine on Vessel
Repair of Engine Block of Yanmar Engine on Vessel

Lock and Stitch Cast Iron Repair – RA Power Solutions

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 – RA Power Solutions

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

 

Metal Stitching of Crack Casting – RA Power Solutions

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.

Metal Locking of Wartsila Diesel Engine
Metal Locking of Wartsila Diesel Engine

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.

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

RA Power Solutions have experienced technicians to undertake metal stitching and metal locking process with guarantee.