metal surgery process Archives - RA Power Solutions

What Is Metal Stitching and Metal Locking? A Trusted Cold Repair Technique: RA Power Solutions

When a metal component cracks—especially in large equipment like engine blocks, compressors, or turbines—repair options can be costly, time-consuming, and risky if not done correctly. One highly effective method that avoids heat, preserves alignment, and restores structural integrity is metal stitching, also known as metal locking.

Understanding Metal Stitching

Metal stitching is a cold mechanical repair process used to fix cracks or breaks in cast metals such as cast iron, aluminum, steel, and bronze. Unlike welding, which uses high heat, metal stitching relies on precision-drilled holes, specially designed stitching pins a nd locks to seal and reinforce the damaged area.
This technique is ideal for industrial applications where heat could distort components or where disassembly isn’t feasible.

Damaged Crankshaft before metal stitching

How the Process Works

Here’s a simplified breakdown of how metal stitching is done:

Crack Detection: Identify and inspect the full extent of the crack.
Drilling Pattern: A series of holes is drilled along and across the crack.
Slot Cutting: A slot is formed to fit stitching locks or keys.
Installing Locks: Metal locks are inserted into the slots to mechanically bind both sides of the crack.
Threaded Studs: In some cases, overlapping threaded studs are used to seal the crack.
Sealing & Finishing: The surface is peened and machined smooth to match the surrounding area.

Why RA PowerSolutions?

At RA PowerSolutions, we specialize in on site metal stitching and metal locking for all types of cast components. There is no need for dismantling or transporting the part.
With decades of experience and hundreds of successful global repairs. We help industries reduce downtime, avoid expensive replacements, and restore strength and performance efficiently.

Our services include:

Metal stitching of engine blocks, compressors, pumps, etc.
On site machining and grinding
Repair of crack-prone components like turbine casings and gearbox housings
ISO-certified technicians and portable tools

If you’re facing a critical breakdown or seeking long-term solutions for metal cracks, RA PowerSolutions is ready to assist with expert, onsite support. Contact us today to learn more or schedule an inspection.

For more details on the Metal Stitching and Metal Locking , Crack Repair by Metal Stitchng email us at info@rapowersolutions.com. Call at +91-9582647131,+91 9810012383.

FAQs:

1. What is metal locking?

Metal locking crack repair process – Metal-lock or metal stitching is a method of repairing fractures to castings, onsite without the use of heat. It involves sinking Metal-lock keys, perpendicular to a fracture. The fracture is then sealed and held rigid by Metal-lace studs

2. How is metal stitching better than welding?

Metal stitching does not use heat, so there’s no distortion or weakening of the material. It preserves the original shape and alignment of the part and is ideal for cast iron, which is prone to cracking when welded.

3. Can metal stitching be done on-site?

Yes, RA Power Solutions specializes in on site metal stitching, allowing us to repair damaged equipment without dismantling or transporting it—saving time, cost, and downtime.

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.

Broken Engine Block Repair | Damaged Engine Bedplate Repairs | Metal Stitching

The repair of broken engine block, turbocharger casing, and 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 damaged engine block, steel components repair, cast iron repairs, and all types of cast components by metal stitching and metal locking process for the last four decades.

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

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 the UK.

Engine Block After Metal Stitching and Metal Locking

Advantages of crack repair and damage casting, cast iron repair by metal stitching, and metal locking process:

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 cracked or damaged components to the workshop.
In most cases, there is no requirement for the disassembly of equipment.
We possess portable tools to execute the repairs on-site.
The time duration for the repair of crack and damaged cast components by metal lock and metal stitching is low.
Metal Stitching and Metal Locking is a permanent crack repair method as no heat is generated which is associated with welding.
The crack and damaged area after repair by metal locking and metal stitching process is restored to its original profile and is also recommended for gas or watertight repair.
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:

Damaged turbocharger casing.
Pump casing and gearboxes.
Fixing Cracked engine block, cam covers, cylinder liners, turbine casings, and all components.
Heavy industrial and mining equipment.

Metal Surgery under Process while Vessel is Sailing

For a detailed repair process of damaged casting by metal locking, damaged engine block, metal stitching, broken engine block repair, and metal surgery please 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.