Metal stitching is a technology which is over 100 years old and now very well proven and established to undertake crack repair or damage of cast components manufactured out of cast iron or aluminium alloy. In some of the cases, the crack repair is also possible in components made of bronze.
RA Power Solutions as a repair company have tried the process of cast iron block repair by metal stitching, metal locking and by welding. We have observed that the repair of damage casting and repair of crack by metal stitching, metal lock and metal surgery is most successful in comparison of welding.
Following are the advantages over the welding process of repair:
- The metal stitching, metal locking is a cold repair of crack, no stresses are developed as no heat is generated.
- In most of the cases, no dismantling of equipment is required.
- In normal situation access for the pneumatic tools is only required.
- Metal lock/Metal stitching being a cold method, no loss of alignment or profile is observed, hence in most of the cases, no machining is required.
- The repaired area by metal lock and metal stitching process is liquid and gas tight.
- With time, it has proved to be almost a permanent repair.
The brief process of metal stitching/metal locking for crack repair in aluminium, bronze and cast iron components is as following:
In order to make the crack repair or repair of damage casting successful by metal stitching and metal lock process, it is important that the damaged area is thoroughly checked for the length, location and number of cracks preferably by MPI equipment.
We suggest that minimum level two or level three qualified technicians should undertake the crack detection inspection by MPI process. In case of non-availability of MPI equipment, the crack detection test by die penetrant test can also be undertaken. It is of utmost importance that no crack should go unidentified which in case left without metal stitching and metal lock can elaborate further and can cost a serious damage to the component and the equipment in totality.
The cracks and the damaged portion should be identified and marked clearly.
The crack metal is replaced with the special metal stitching pins which are placed by drilling and tapping.
To pull the sides of the crack together insertion of special allow metal stitching pins result to the continuous formation of row of interlocking stitching pins which in turn develops a strong and pressure-tight repair. The master locks are installed across the joint line by drilling process to give additional strength.
Quality of stitching pins and locks
It is important that the stitching pins and locks used for metal stitching and metal locking should be made out of high-grade steel, steel pins being stronger than the cast iron are usually used to repair the crack in cast iron components.
We also use stitching pins and master locks of different alloy to repair aluminium, bronze and steel castings.
Availability of experienced technicians
RA Power Solutions Pvt. Ltd. takes pride in claiming that we have a dedicated team of technicians to undertake the repair by metal lock and metal stitching process. These technicians have vast experience and knowledge to undertake the serious and most complicated damages that take place in the industries. It is also advisable to get the job executed by the engineers who have spent their lifetime in successfully executing the crack repairs specializing in diesel engines.
Warranty extended by RA Power Solutions:
In the last forty years of our extending metal locking and metal stitching services to various industries, we have successfully repaired more than 1500 engine blocks, casings, components made of aluminium, bronze and alloy casting. We have helped the ship owners and owners of the heavy engineering plants to save enormous amounts of money by reducing the equipment downtime and by avoiding the purchase of new equipment.
All the jobs executed by us are guaranteed for satisfactory performance. We are proven to be cost-effective and can depute our team of technicians along with consumables in a short notice.
This blog is written by Mr. Raj Shahani (Managing Director of RA Power Solutions). He has forty years of experience in the field of engine repair and is a technical adviser to various shipping and heavy industries based all over the world.
For more information on fix cracked engine block, cold metal stitching engine block, repairing cast iron, and crack repair by metal stitching contact us at rajshahani@rapowersolutions.com or info@rapowersolutions.com or call us at +91-9582647131, or +91 9810012383.