Gone are the days when in case of cracks in aluminium cast components were rejected and replaced by new ones as it was not possible to undertake the crack repair in aluminium cast components or the components which used to get damaged due to accidents. The welding process in some cases was used for aluminium crack repair, but it was not a proven method or the right technology of repair, as results always were not satisfactory.
RA Power Solutions undertakes aluminium crack repair by metal stitching, metal locking and metal surgery process which is a cold process of repair of cracks of aluminium components, cast iron components, and cast steel.
Generally, all the heavy components manufactured out of aluminium casting can be repaired by metal stitching, metal locking and metal surgery.
Cracked Aluminium Cylinder Head Repair
It is not possible to undertake repair of cracks & damage to cylinder head, cylinder liner, and components manufactured of aluminium or cast iron by welding process due to the generation of heat.
A few of these are described below:-
- Crack repair of aluminium cast pistons.
- Crack repair of engine block manufactured out of aluminium alloys.
- Damaged or cracked pump casings, turbocharger casings, and turbine casings can be repaired by the metal locking and stitching process.
- Repair of cylinder liners, and cylinder heads manufactured out of cast iron or aluminium.
- Aluminium Piston Crack Repair
In order to undertake aluminium crack repair or repair of damaged aluminium casting, cast iron or steel casting components.
We follow the procedure given below:-
- Crack detection.
- It is important that prior to starting the process of crack repair, the cracks are properly identified, and the location is marked. The cracks are checked by the following methods.
- Visual Inspection
- Dye penetrant test of crack on the damaged area.
- Crack detection by MPI using the high-intensity magna flux torch.
- Pressure Testing
We strongly recommend that in case of red oxide or paint on the surface of a damaged component, it should be thoroughly removed.
- Aluminium Crack Repair by Metal Stitching and Metal Locking process
After the location of the crack or cracks is identified, the cracks are repaired by metal stitching and metal locking process.
We use the following special pins and locks for metal locking.
- Standard threaded pins – They are straight-thread L-Series pins. They are designed to seal by interference fit after threads. The threaded pins exert spreading pressure for sealing, seat retention and crack removal.
- Spiral thread hooks for radial drawing force are used which creates structural integrity, seal leaks and also prevent crack propagation.
The repair of cracks in aluminium cast components requires special tools and experience as the aluminium casting cuts easier than the cast iron, RA Power Solutions regularly undertakes repair of aluminium cast iron and steel casting components and has executed repairs successfully in countries like Dubai, Greece, Maldives, Malaysia, Singapore, Madagascar, Nigeria, South America, UAE, Germany, Monaco, Qatar, Sri Lanka, Bangladesh, Italy, Spain, Czech Republic, UK, Philippines, 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 44 years in the field of Power, Heavy and Shipping industries. He is a Technical Advisor to many shipping and heavy industries across the globe.
Mr. Shahani is one of the most enthusiastic professionals, and he has all the brilliance of an exemplary leader. He 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 Piston Repair by Metal Locking, Turbine casing crack repair on-site, Cracked Aluminium Cylinder Head Repair and Cylinder liner head repair contact rajshahani@rapowersolutions.com or info@rapowersolutions.com or call us at +91 9582647131 or +91 9810012383.