RA Power Solutions was approached by a company advising about the damage of Gearbox base manufactured out of cast Iron. This Gearbox is used for the main engine to Propeller shaft. The base was broken into pieces.
The details of damage observations are mentioned below.
Sr No. |
Description |
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1 |
Repair of Cracked Gear Box for Main |
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2 |
Length of the cracks Inboard leg |
160 mm |
3 |
Length of the cracks Outboard leg |
148 mm |
4 |
Thickness of casting cracked |
55 mm |
5 |
Engine Make & Model |
Yanmar Model no. YXHG-2500LM |
6 |
Place of Execution of Job |
Kandla Port Gujarat |
The thickness of casting was observed as 55mm that is more than 2 inch.
RA Power Solutions undertakes the repair of crack or damaged cast iron, Aluminum and bronze heavy components by metal stitching or metal locking process which is simple and is a proven process of repair of damage and cracked casting.
Repair of Crack Gearbox by RA Power Solutions technicians:
- RA Power Solutions deputed two technicians for undertaking inspection and metal stitching of Gearbox.
- After removal of paint including the Red oxide the cracked area was subject to Dye penetrant inspection and also MPI by high intensity magnaflux torch to check the location,length and intensity of the cracks.
- As mentioned above the cracks measuring 160 mm and 148 mm length were observed.
- The thickness of casting was 55 mm which made the repair by metal locking & metal stitching process more difficult.
- Our technicians executed the damage Gearbox repair successfully by using the special master locks, locks and keys.
Broken Gearbox base |
Clamping of Damage potion |
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Broken Part of Gearbox |
Process of Crack Repair |
Advantages of Crack Repair by Metal Lock process:
- The main advantage of crack repair by metal locking & metal stitching is that in majority of cases the crack repair can be executed onsite without dismantling of the equipment. This not only saves the time & money but also saves from the botheration of transportation of heavy components to the workshop.
- It is a cold process and does not require any major machining. It is very important in case of repair of engine housing where the requirement of alignment is within 0.03 mm.
- No heat is generated hence no distortion.
- With the introduction of the latest technology, process and experience of our technicians, we are able to successfully repair the engine major components like cylinder liner, cylinder head, turbocharger casing etc
We have been regularly executing the metal stitching/ metal locking & repair services in Argentina,Bahamas, Barbados, Bermuda, Bolivia, Brazil, Canada, Chile, Colombia, Costa Rica, Cuba, Dominican Republic, Ecuador, El Salvador, Guatemala, Guyana, Haiti, Honduras, Jamaica, Mexico, Nicaragua etc.
This blog is written by Mr. Raj Shahani (Managing Director of RA Power Solutions India Pvt. Ltd.).
Mr. Shahani is a highly experienced business leader with rich experience of more than 40 years in the field of Power, Heavy and Shipping industry. He is Technical Adviser to many shipping and heavy industries across the globe.
Mr. Shahani is one of the most enthusiastic professional and he has all the brilliance of an exemplary leader. Mr. Shahani is an extremely effective coach and mentor of teams and is adept at providing leadership in a global, cross-cultural environment.
For more information on metal locking and stitching techniques, and crack repair techniques contact us on rajshahani@rapowersolutions.com, or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.
Process of metal stiching of Broken piece |
Metal Stitching of damaged casting |
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Process of Repair of Gearbox |
Casting after Repair |
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