This process is trusted in industries like,

• Marine engines and crankcases
• Power plants and turbine casings
• Pump and compressor housings
• Heavy industrial machinery

Why Not Welding?

Welding large cast components often causes:

• Heat distortion
• Loss of strength due to metallurgical changes
• Crack expansion or new cracks
• Metal stitching avoids heat damage and preserves the original material strength.

How Keys & Locks Work in Metal Stitching

The core of Metal stitching involves installing metal keys (locks) and stitching pins into the crack

Step-by-Step Explanation:

Step 1: Drilling and Stop-Holing

• Small holes are drilled at both ends of the crack.
• This prevents the crack from spreading during the repair.

Step 2: Installing “Locks” (Metal Keys)

• A series of overlapping slots are machined along the length of the crack.
• Technicians insert precision-engineered metal locks (keys) into the slots

Purpose of Keys/Locks:

• They mechanically pull both sides of the crack tightly together.
• They distribute load and stress evenly across the repaired area.
• The locks exceed the strength of the original casting and restore structural integrity

Step 3: Installing Stitching Pins

• Holes are drilled perpendicular to the crack.
• Technicians screw stitching pins into the holes to fill and seal the crack,

Purpose of Stitching Pins:

• They hold the metal in compression.

• They make the repair pressure-tight, preventing leaks of oil, coolant, or gas.

Step 4: Surface Finishing

• The repaired area machined flush.
• After finishing, the repair hides the crack and restores the component to OEM tolerances.

Advantages of Using Keys & Locks in Metal Stitching:

Where This Method Is Used

Metal stitching with keys and locks is commonly used for:

• Cracked diesel engine blocks
• Turbine and pump casings
• Compressor housings
• Marine engine frames and bedplates
• Generator casings

Whether the crack is small or several feet long, the stitching process scales to the size and location of the damage.

Metal stitching using precision metal keys and stitching locks is a reliable, proven, and cost-effective cold repair technique. Unlike welding, it involves zero heat—meaning no distortion, no stress, and no change in material properties. This method restores the structural integrity of cracked cast components and saves industries from huge downtime, dismantling, and replacement costs.

And when it comes to execution, RA Power Solutions is one of the leading global experts in metal stitching and metal locking. With four decades of experience and thousands of successful repairs, we specialize in restoring engine blocks, turbine casings, cylinder liners, compressor housings, and other critical equipment right at the site — anywhere in the world.

For more information on metal stitching repair of engine block cracks, metal stitching crack repair, engine block crack repair, and Crack in Cylinder Liner, please email us at rajshahani@rapowersolutions.com or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

FAQs:

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All the repairs executed by us are on-site and without disassembly of the main equipment.

The procedure for metal locking and metal stitching of damaged components, as followed by RA Power Solutions, is as follows:

• A drilling fixture is attached at right angles to the crack. A hole pattern is drilled and repeated at intervals of 3/4 to 1-1/4 inches apart.
• The metal between each drilled hole is removed with the help of pneumatic tools to form a slot. The stock removed is narrower than the drilled hole, thus forming a serrated opening.
• We insert preformed locks of high-tensile alloy into the drilled slot. We peen the locks into the slots one on top of the other in an overlapping pattern. The casting thickness limits the depth, and we determine it by the required strength.
• After the locks are installed, holes are drilled and tapped, and threaded fasteners are applied. These are spotted along the entire length of the crack, overlapping one another. Their purpose, in part, is to fill the fracture with new metal and provide a pressure seal.
• The entire repair area is peened flush and finished ground. Painted if required.

The Metal Locking technique can be used to repair everything from casting faults. The broken machinery and improper machining to intricate items such as marine engines and gears. We can work on a wide array of materials, including work-hardened and heat-treated items.

RA Power Solutions extend Cast Iron Repair, metal stitching/ metal locking services all over the world including countries like Dubai, Oman, Saudi Arabia, Qatar, Abu Dhabi, Sharjah, Ajman, Umm Al-Quwain, and Fujairah, Bahrain, Kuwait, Iraq, Antigua and Barbuda, Belize, Dominica, Dominican Republic, Grenada, Guyana, Haiti, Jamaica, Saint Kitts and Nevis, Saint Lucia, Saint Vincent and the Grenadines, Trinidad, and Tobago, etc.

For more information on metal surgery, metal lock, and metal stitching, contact us at rajshahani@rapowersolutions.com or info@rapowersolutions.com or call us at +91 9582647131 or +91 9810012383.

FAQs:

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In the past, technicians repaired cracks in cast iron with the traditional welding process. The industry no longer practises this method because welding repairs do not always deliver successful results.

We undertake onsite cast iron repairs and repairs of aluminium and cast steel. All the repairs undertaken by a cold process.

The main advantages are as follows:

Benefits of cast iron repair, aluminium casting, and steel casting repair by metal lock and metal stitching

• Cast iron repair and damage casting repair are possible on site, and there is no requirement to disassemble of damaged component from the main equipment and send it to the designated workshop.
• RA Power Solutions follows the metal stitching and metal locking process to repair cracks in grey iron, steel casting, or aluminium. The process is cold, and it does not generate heat.
• Since the cast iron repair by metal stitching and metal locking is a cold process, there is no loss of alignment or change in the original profile of the component.
• In most cases, there are no need for machining after the damage or crack casting is repaired. This is of great benefit in comparison to the welding process followed by a few companies for crack repair.
• The cast iron crack repair by metal stitching and metal locking process restores to its original strength of the casting and is a watertight and gas-tight repair.
• We execute cast iron crack repairs in minimum time. Our process drastically reduces the downtime of the equipment and the entire plant.

We repair cracks in the casting of grey iron, steel, or aluminium. A few applications mentioned below:

• Repair of cracked engine block, inspection window, liner sitting area in entablature, etc.
• Repair of damaged cylinder liners, pistons, cylinder head, and turbine casing.
• Repair of damaged heavy industrial machinery.
• Repair of damaged gearboxes and pump casings manufactured of Aluminium, cast steel, and grey cast iron.
• We successfully repair all types of cracks in cast iron, aluminium casting, and steel casting.

For more information on cast steel casting, the method of repairing cracks, metal surgery, damaged casting repair in Gambia, and metal stitching, contact us at rajshahani@rapowersolutions.com or info@rapowersolutions.com or call us at +91 9582647131 or +91 9810012383.

FAQs:

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At RA Power Solutions, it is now possible to salvage and save what is otherwise a rejected component or a heavy piece of machinery.

The repair of damaged cast components by traditional welding process is not effective and reliable. In fact, in most cases, due to welding, more damage to the components is reported.

RA Power Solutions has forty-five years of experience in metal stitching, metal locking, and metal surgery

A company well known for extending all over the world for onsite repair of crankshaft and major components has the expertise to repair major and heavy components that are damaged due to accidents. Our clients are from cement plants, power plants, oil rigs, heavy engineering components, etc.

With the experience of forty-five years in the field of repair of damaged components by metal stitching, metal locking, and metal surgery, we are confident to say that the results obtained after repair are almost a hundred percent. All the jobs of metal stitching undertaken by us are guaranteed for satisfactory performance.

In case of an accident, we have the advantage over other companies. All our technicians are trained in metal stitching and metal locking processes. Training is done in our in-house training school based in IMT Manesar, Gurgaon. They have a valid CDC and a U.S. visa. They can fly on any plane or vessel all over the world. Equipment and consumables can be carried as accompanying baggage in a short time.

Thus reducing the breakdown time of a power plant or a vessel.

The main advantage of Cast Iron Repair by Metal Stitching:

• There is no requirement to dismantle the parts and send them to the workshop for repair.
• The metal stitching, metal locking, and metal surgery for crack repair of damaged casting are undertaken onsite. This avoids the high cost associated with disassembly and transportation.
• No heat is generated, which is associated with the welding process.
• Due to the cold process, no distortion of profile takes place, and in most cases, machining is not required.
• The repair area after metal stitching and metal locking is restored to its original strength with air and water fight repairs.
• In some cases, we apply special chemicals after repairs are completed.

We have been regularly executing metal stitching, metal locking, metal surgery & repair services in Iraq, Iran, Dubai, Oman, Saudi Arabia, Qatar, Abu Dhabi, Sharjah, Ajman, Umm Al-Quwain, Fujairah, Bahrain, Kuwait, Antigua and Barbuda, Belize, Dominica, Dominican Republic, Malaysia, Indonesia, Madagascar, Vietnam, Grenada, Guyana, Haiti, Jamaica, Saint Kitts and Nevis, Saint Lucia, South Korea, Saint Vincent and the Grenadines, Trinidad, and Tobago, etc.

For more information on Engine Block Stitching and turbine casing crack repair on site, Aluminum Crack Repair, contact us at rajshahani@rapowersolutions.com or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

FAQs:

The post Cast Iron Repair | Cast Steel | Aluminum Crack Repair By Metal Stitching, Metal Locking And Metal Surgery appeared first on Metal Stitching and Metal Locking Services | RA Power Solutions.

In case of cracks repair in casting and repair of damaged heavy components, the consumables like locks, keys, master locks, etc, used must be of high tensile, again the job of metal stitching and metal locking is to be executed by experienced technicians.

RA Power Solutions has excellence in both areas. We import keys, locks, and master locks from Europe. These are sourced from companies with over a hundred years of experience. We have in-house technicians who specialize in crack repair by metal stitching and metal locking. They have been executing this work for more than forty-five years.

RA Power Solutions is the only company that can also execute the crack repair by metal stitching & metal locking onsite. The repairs are also possible while sailing the vessel.

The broad range of applications of crack repair by Metal Stitching/Metal Locking is as follows:

• Damaged engine bed plate, cylinder head, turbine casing, etc.
• Repair of heavily damaged industrial equipment.
• On-site repair of all the machinery installed on the vessel.
• Repair of damaged pump casings, gearboxes, and forging hammers.

We have been regularly executing metal stitching/ metal locking & repair services in Dubai, Oman, Saudi Arabia, Qatar, Abu Dhabi, Sharjah, Ajman, Umm Al-Quwain, and Fujairah, Bahrain, Kuwait, Iraq, Antigua and Barbuda, Belize, Dominica, Dominican Republic, Grenada, Guyana, Haiti, Jamaica, Saint Kitts and Nevis, Saint Lucia, Saint Vincent, and the Grenadines, Trinidad, and Tobago, etc.

For more information on engine block stitching, repairing cast iron, and turbine casing crack repair on site, contact us at rajshahani@rapowersolutions.com or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

The post Cast Iron Repair | Repair Of Damaged Casting | Metal Lock | Metal Stitching appeared first on Metal Stitching and Metal Locking Services | RA Power Solutions.

The details of damage observations are mentioned below:

The thickness of the casting was observed as 55 mm, which is more than 2 inches.

RA Power Solutions undertakes the repair of cracked 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 to undertake the inspection and metal stitching of the Gearbox.
• After the 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, cracks measuring 160 mm and 148 mm in length were observed.
• The thickness of the casting was 55 mm, which made the repair by the metal locking & metal stitching process more difficult.
• Our technicians executed the damage, and the Gearbox repair was completed by using the special master locks and keys.

Advantages of Crack Repair by Metal Lock process:

• The main advantage of crack repair by metal locking & metal stitching is that in the majority of cases, the crack repair can be executed onsite without dismantling the equipment. This not only saves 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 the case of the repair of the 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 can successfully repair the engine’s 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.

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 at rajshahani@rapowersolutions.com, info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

FAQs:

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We undertake the repair of the damaged and cracked engine block by metal stitching and metal locking process, the advantage of which is as follows.

Repair Of Cracked And Damaged Engine Block By Metal Stitching And Metal Lock Process:-

The repair by metal lock and metal stitching technique is a proven method. It is used for repairing damaged engine blocks, turbo casings, cylinder liners, pistons, and other major spares of diesel engines and heavy mechanical equipment.

The area of the crack must be identified and marked. We undertake crack detection by MPI and the dye-penetrant method, depending on the thickness of the casting. When necessary, we perform metal stitching on both sides of the damaged area. We provided that there is sufficient space for the approach of our pneumatic tools.

RA Power Solutions uses high-quality metal keys, metal locks, and consumables. Combined with the expertise of our experienced technicians, this ensures successful repairs through metal stitching and metal locking.

We have been regularly undertaking repair of engine blocks, compressors, turbochargers, and all cast iron, bronze, and aluminium for the following makes of engines:-

• Akasaka
• Mitsubishi
• Daihatsu
• Yanmar
• Hanshin
• Kobe Mitsubishi
• Caterpillar
• Wartsila
• Deutz-KHD
• Volvo Penta SKL
• MAK
• Sulzer
• MAN B&W
• SKL
• MTU MAK
• Pielstick
• MWM MAK

We have been regularly executing the repairs 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.

Mr. Shahani is a highly experienced business leader with 45 years of rich experience in the field of Power, Heavy, and Shipping industry. He is a Technical Adviser 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. 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 a cracked engine block, cracked engine block repair, repair of damaged engine block, metal stitching technique, or cracked and damaged engine block, contact us at rajshahani@rapowersolutions.com or info@rapowersolutions.com or call us at 9582647131 or 9810012383.

FAQs:

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This process of Onsite Crack Repair Has replaced the old and conventional method of crack repair by welding. Crack repair by metal stitching and locking is becoming popular worldwide.

The main advantages are as follows:-

• In this time of recession, get your equipment repaired successfully on site and avoid replacement.
• In 99% of cases of accidents, crack repair by metal stitching has proved to be successful.
• Can you afford a long breakdown in your plant? No, get your equipment back in service in a few hours.
• A fantastic solution and technological innovation for crack repair without disassembly of the equipment. Repair is possible on-site, metal surgery, even on ships and on the high seas, or at remote heavy engineering plants.
• In most cases, no machining is required, as no heat is generated.
• A pressure-tight seal can be achieved.
• The metal lock and metal stitching process is recognised by the classification societies.

Expertise available with RA Power Solutions for Forty-Five Years:

You cannot trust the repair of your expensive equipment to a company that is not experienced. RA Power Solutions, with 45 years of experience, has technicians who have spent their lifetime successfully repairing the engine and heavy machinery components that have been seriously damaged. The successful repair of cracks and damaged components needs proper planning and execution.

We have been regularly repairing the cracked components of the most popular engine makes like Wartsila, Daihatsu, Mirrless Blackstone, Yanmar, Allen, MAK, MAN, B&W, Sulzer, Caterpillar, etc.

The consumables used by us to undertake the repair by the metal stitching process are of high quality and proven for their satisfactory performance. The effective and proven alloy of MN211 AND MN 555 is used for undertaking the repair by metal stitching.

RA Power Solutions has successfully executed thousands of crack repair jobs all over the world. The cost of repair offered by us is the lowest in the market.

For more information on onsite metal surgery, engine block metal locking, and turbine casing crack repair onsite contact us at rajshahani@rapowersolutions.com or info@rapowersolutions.com or call us at +91 9582647131 or +91 9810012383.

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