Metal Stitching Services - RA Power Solutions

Metal Stitching And Metal Locking Services For Crack Cast Iron Repairs | Global Leaders

RA Power Solutions specializes in metal stitching and metal locking, offering a trusted and effective solution for repairing cracked or damaged cast iron components. Unlike traditional welding, which can cause heat-induced stress and distortion, our cold repair techniques ensure structural integrity without compromising the original material properties.

What is Metal Stitching and Metal Locking?

Metal stitching and metal locking are specialized cold repair techniques used to restore cracked or damaged cast iron and other metal components without welding or heat application. These methods are widely used in industries where heat-based repairs could cause further damage, distortion, or weakening of the material.

Metal Stitching
Metal stitching is a mechanical repair process that joins broken metal parts by inserting precision-engineered metal stitches along the crack. These stitches restore the strength and integrity of the component while keeping the original structure intact. The process involves:

Drilling holes along the crack in a controlled manner.
Connecting the holes with a milled slot to create a secure stitching channel.
Installing metal stitches or keys that pull the broken sections together, creating a seamless repair.

Metal Locking
Metal locking is an advanced reinforcement technique that works alongside metal stitching. And Enhance the repair’s strength. It involves placing metal locks perpendicular to the crack to distribute stress evenly, preventing further damage. This makes the repair permanent, durable, and capable of withstanding high loads and pressure.

Why Choose RA Power Solutions?

44+ Years of Experience – The only company in India with decades of expertise in metal surgery, metal locking, and metal stitching.
Onsite Repairs – No need to dismantle heavy machinery; we repair components at your location, minimizing downtime.
Global Reach – Our team has successfully completed over 1000 crack repair projects worldwide, serving industries across various sectors.
Trusted by Leading Companies – Major corporations in India and internationally rely on us for cost-effective and high-quality repairs of heavy cast iron components.

At RA Power Solutions, we use portable and lightweight equipment, allowing our skilled technicians to provide onsite repair services at any plant or site in India and worldwide. With over 44 years of experience, we are the only company in India. With a proven track record in metal locking and metal stitching. Our expertise has made us a trusted partner for major companies globally.

Leading industries in India and across the world rely on our services. For crack repair and restoration of heavy cast iron components.
For more information on metal stitching service providers, metal stitching, cast iron stitching, or cracked engine block repair. please email us at rajshahani@rapowersolutions.com, or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

FAQs

What is the metal locking process?

The metal locking process is a mechanical repair method used to fix cracks or breaks in metal components without welding. It involves inserting metal locks and pins to restore structural integrity, making it ideal for cast iron or machinery repairs where heat from welding is not suitable.

How does metal stitching work?

We repair cracked metal by using special stitching pins. These pins are carefully installed by drilling and tapping along the crack, pulling the sides together. This creates a strong, interlocking row of pins that seals the crack and restores pressure-tight strength.

What is the best way to repair cracked metal?

At RA Power Solutions, we use several proven methods to repair cracks commonly found in engine components. The most popular techniques include:
Tapping and Plugging – Sealing the crack by inserting metal plugs to restore strength and prevent leakage.
Sealants – Applying industrial-grade sealants for minor cracks that don’t require heavy machining.
Sleeve Insertion – Fitting a strong metal sleeve to reinforce and protect the damaged area.

How to do metal stitching?

Holes are carefully drilled along the length of the crack, then tapped and filled with special stitching studs. Each stud overlaps slightly with the previous one, creating a tight, pressure-resistant seal. This is the core step of the metal stitching process, where the crack is effectively replaced by a solid row of studs. After installation, the surface is peened for added strength, and any excess material is smoothly ground off.

What is cold metal stitching?

Metal stitching is a mechanical repair method where we carefully drill and tap along the length of the crack, then insert special interlocking stitching pins. This creates a strong, pressure-tight seal—without the need for heat or welding.

Repair of Crack Cast Metal by Metal Stitching Services | Cast Iron Engine Block Crack Repair

It is observed that cracks repair in cast iron components develop due to exposure to excessive heat or mechanical failures. Sometimes it is difficult to arrange for the new part due to long delivery or exorbitant price.

RA Power Solutions undertakes repair of cracked cast metal or aluminium components by metal stitching and metal locking process. It provides permanent crack repair solutions without the generation of heat associated with the welding process. The main advantage of cracking or damaged cast iron or aluminium components by metal stitching and metal locking is that it can be performed onsite avoiding the considerably high cost of labour for disassembly of the equipment and transport to the designated workshop.

The repair of cracks cast metal by metal stitching and metal lock process restores the surface area to the original dimensions and profile. Very rarely there is a requirement for machining. The repairs are also watertight and gas-tight.

Onsite Repair of Engine Block by Metal Stitching & Metal Locking

RA Power Solutions with experience of more than four decades. We have experienced technicians who have undertaken the most complex crack repair jobs through metal stitching and metal lock processes. The technicians carry pneumatic portable tools and consumables to the site. We have executed thousands of repairs of cracked components, a broad description of which is as follows:

Repair heavy earthmoving and mining machinery.
Repair of high-capacity turbines, alternators, turbocharger casings, and parts.
Cracked engine blocks, cylinder heads, pistons, and cylinder liners.
Heavy-duty industrial machine.

Pulverizer of Cement Plant under Repair by Metal Stitching Metal Locking — Pulverize of Cement Plant Under Repair By Metal Stitching Metal Locking

Repair of Piston by Metal Locking & Metal Stitching under Process

The consumables used by RA Power Solutions for the repair of crack cast metal by metal stitching and metal lock have the following properties which result in permanent repair with a guarantee.

I) Locks:

The locks of different designs are used in the process of repair of cracks by metal lock and metal stitching according to the intensity of the crack, length and thickness of the casting.

Special Metal Locks & Keys for Repair of Engine Block — Special Metal Locks & Keys For Repair Of Engine Block

The locks used by us are made of precision-cut high-grade steel and are able to withstand high tensile forces more than the original casting.

II) Stitching Pins:

The stitching pins used by us have special threads which make the process failure-free. The pins are manufactured out of high-grade steel and have higher tensile strength than the cast iron.

Engine Block After Repair by Metal Stitching & Metal Locking Process

For your requirement of crack repair on-site in a Power Plant or onboard a vessel, you may contact RA Power Solutions. All our technicians have valid CDC and can fly to any destination in the world on short notice.

For more details on fixing a cracked engine block, metal surgery process, repair crack cast iron, engine block repair, crack repair of components, and cast iron engine block crack repair please email us at rajshahani@rapowersolutions.com, or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

Overhauling of Main Engine Repair | Repair of Engine Metal Stitching of Damaged Block

RA Power Solutions received an emergency call from a Steel Company based in Indonesia regarding damage of their Engine SULZER 6RND68.

On arrival of our team of engineers, it was observed that lower engine block of SULZER 6RND68 was damaged badly. Hence it required disassembly of complete engine, overhauling and repair of engine block by metal stitching & metal locking.

Following is the brief of job description executed:

Inspection and overhaul of the cylinder covers including the fuel and starting valves located in the covers. The cylinder covers cooling spaces were also inspected, cleaned and fitted back with new O-rings.
Dismount, Inspect and overhaul the exhaust valves, renewed the seals and grinding the valve spindles.
The cylinder liners were cleaned, calibrated and honed in order to restore the liners running surfaces and remove ovality. This ensured that the piston rings perform better and this will lead to a better overall cylinder condition, compared to if honing had not been done. The cylinder liners cooling spaces were also inspected, cleaned and fitted back with new o-rings.
Replacement of thrust block pads and correction of end play.
Metal locking of damaged Engine block by our technicians.

Special Keys & Locks Used in Metal Stitching Process

Repair of Engine Block by Metal Stitching is in Process

Inspected and adjusted the chain drive.
Retightened the stay-bolts, holding down bolts end chocks.
Took bearing clearances with a telescopic feeler gauge and checked bearing edges by wire gauges.
Crankshaft alignment measurement was taken with dial gauge (autolog method)
Conclusion: The engine was tested on full load for 72 hours & all the parameter were recorded. The engine is performing satisfactorily.

Repair & Overhauling of Engine is in Process

Inspection of Engine Spare Parts is in Process

For more details regarding Metal Stitching of Damaged Block, overhauling of engine, repair of engine metal stitching of damaged block, crankshaft grinding, and engine block repair please email us at rajshahani@rapowersolutions.com, or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

Metal Locking and Metal Stitching Process- RA Power Solutions

Metal locking and metal stitching is a process of repair of cast metals having different metallurgy without the necessity of wielding. Metal locking and metal stitching is a cold and proven method of repair of cast iron and cast steel components.

The advantage of crack repair and broken casting by metal locking and metal stitching is that it can be carried out at the site anywhere and it even does not require dismantling of the equipment in most of the cases this results to considerable saving of time and money. Crack and broken casting repair is proven and is old method for crack repair it is widely used for heavy-duty plant and equipment, ship engine, heavy-duty forging presses, etc.

**Metal Stitching of JIBB Plate of 225 Ton**

We regularly execute crack repair by metal locking and metal stitching of following parts:

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. all Cast equipment etc.

RA Power Solutions is a leading provider of metal locking services. We have a team of experienced engineers and technicians who are skilled in using this technique to repair a wide variety of castings. We have a proven track record of success, and we are confident that we can provide you with a high-quality repair that will meet your needs.

If you have any questions about our services please contact RA Power Solutions. We would be happy to answer your questions and discuss your specific needs.

For more information on cold metal lock stitching, metal stitching service provider, metal stitching cast iron, crack repair, and metal stitching of engine block email us at rajshahani@rapowersolutions.com, or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

Metal Stitching and Metal Locking of Engine Blocks – 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.

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

RA Power Solutions Pvt. Ltd. undertakes metal stitching and metal locking of casting and has successfully repaired various major components of a 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 equipment etc.

In the last 45 years, more than 10,000 jobs of crack repair have been successfully executed.

Stitching Pin Used in Metal Stitching Process

Metal Stitching Done in Broken Area of Generator

RA Power Solutions is proud to say that we have a dedicated team of specialists who specialize in metal lock and metal stitching repairs. We promise good performance on all of our jobs. We have shown to be cost-effective and can deploy our team of professionals and consumables on short notice. We have recently expanded these services to Dubai, Greece, Maldives, Malaysia, Singapore, Madagascar, Nigeria, South America, UAE, Germany, Monaco, Qatar, Sri Lanka, Bangladesh, Italy, Spain, Czech Republic, UK, Nepal, Philippines, Jordan, Libya, Kuwait, Egypt, Morocco, Yemen, Bahrain, Tunisia, Sudan, Oman, Algeria, Saudi Arabia, Iraq, and others.

For more details regarding crack repair by metal stitching, engine block repair, cold metal lock stitching, and cast iron by metal lock & metal stitching, please email us at rajshahani@rapowersolutions.com, or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.