In case of cracks in cylinder liners, pistons, or cylinder heads in heavy-duty engines, compressors, or turbines there is no need to reject them as now it is possible to repair the crack by a cold process called metal lock and metal stitching. This is a proven procedure of crack repair which has been followed for over 47 years.

We Undertake Crack Repair of the Following Components and Equipment

• Components Manufactured out of Cast Iron, Cast Steel, etc.
• Cylinder Liners, Cylinder Blocks, and Components Have Higher Hardness.
• Piston Manufactured Out of Aluminium
• Bronze Components

RA Power Solutions regularly undertakes repair of main engine components, which develop multiple cracks at different locations and lengths.

The following components were damaged and successfully repaired by the Metal Locking/Metal Stitching process

• In the case of a main engine, Cylinder liners developed multiple cracks from the outer diameter. The cylinder Liner length and inner diameter were 1500 MM and 600 MM respectively. We measured the cracks from 15 mm to 150 mm. RA Power Solutions Pvt Ltd repaired them successfully using the metal locking and metal stitching process. The repairs perform satisfactorily. The photographs below show the team carrying out the work.
• The engine block of the main engine also developed cracks in different locations. These cracks were repaired on board the vessel by Metal Locking and Metal Stitching Process. RA Power Solutions has over 47 years of experience in the repair of cracks, developed in the casting of heavy components.

For more information on metal stitching repair of engine block crack, 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.

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The crack repair developed in high-casting components is executed onsite without dismantling the main equipment. RA Power Solutions has developed special alloy keys and locks that have almost ten times more strength than the original casting. Now it is possible to repair the cracks that develop in large, heavy-duty cylinder liners. The cracks repaired are mainly in the non-operational area of the cylinder liners. The repair of cracks in large cylinder liners has become popular, as in most cases, it is not possible to arrange the replacement of the cracked liners with new ones.

RA Power Solutions has saved a number of engines by repairing damaged cylinder liners. Our technicians repair cracks using our metal locking and metal stitching process

We regularly undertake the repair of engine blocks, compressors, and all cast iron, bronze, and aluminum components for the following engine makes:

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

We have been regularly providing metal stitching, metal locking, metal surgery, and repair services in Iraq, Iran, Dubai, Oman, Saudi Arabia, Singapore, Russia, Qatar, Abu Dhabi, Sharjah, Ajman, Umm Al-Quwain, Fujairah, Bahrain, Gambia, 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 details on the repair of engine blocks, metal surgery, Crack Repair Of Cylinder Liners and MAN engine cylinder liners, please email us at rajshahani@rapowersolutions.com, or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

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Metal stitching and metal locking is a simple but proven process of repairing cracks in heavy components without following the wielding method, which generates excessive heat.

We observe that heavy components made of cast iron, bronze, cast steel, and aluminium often get damaged due to accidents. When the damaged portion of the casting breaks into pieces, replacement with a new component is usually not possible. A new part is expensive, takes time to manufacture, or belongs to obsolete equipment.

RA Power Solutions has experienced technicians who cut off the damaged portion of the component completely. They make a new casting of cast iron, cast steel, or aluminium as per the original component and bring it to the site. The team assembles the new casting properly and metal stitches it using the best quality metal keys and locks.

The photographs shown in this blog are of MAN main engine model SMIT MAN R666W (Main Engine Port Side) which met with a serious accident. In this case, we have successfully repaired the engine block, cylinder liner, and piston having multiple cracks, lengths measuring from 75 mm to 190 mm.

Advantages of repair of damage casting and crack by metal lock and metal stitching process.

This method of crack repair is the cheapest and can be executed in a short time. Onsite metal stitching repair is undertaken using our in-house trained technicians and consumables. Crack repair and repair of damage casting can be done in any part of the world and on board the vessel as our technicians have valid passports and seaman books. The process of crack repair by metal lock and metal stitching is approved throughout the world including Lloyds.

For more details regardingCrack repair in cast iron, crack repair of aluminium and cast iron repair by metal lock and metal stitching, please email us at rajshahani@rapowersolutions.com, or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

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The following are the main observations after the inspection of the cylinder liners and engine block:

The damaged cylinder liners and cylinder block were subjected to a crack detection test by MPI. RA Power Solutions uses a high-intensity Magna Flux torch to detect the cracks. Our technicians are also level three qualified to undertake the MPI test.

The details of the crack observed in the cylinder liners and cylinder block of the MAN main engine are as follows:

• Cylinder Liners: A crack having a length of approximately 150 mm was observed.
• In the case of the engine block, two numbers of cracks were observed.

1. A crack having a length of about 120 mm was observed in the cylinder liner sitting area on a fuel pump side.
2. A crack measuring about 130 mm was observed in the cylinder liner sitting area on the exhaust side.

The hardness of the cylinder liner was observed between 220-250 HB.

Repair undertaken by RA Power Solutions:

In the case of cylinder liners, the crack was repaired from the inside and from the outer diameter as well by a metal lock process. We used special alloy locks and keys to repair the crack.

The two cracks in the engine block liner sitting area were repaired by a metal lock. After repairs, the proper grinding and polishing were done on the crack area to maintain the specified tolerance.

The liners were assembled in the presence of our technicians. The engine was put into operation after the leak test. The performance of the engine after crack repair of cylinder liners and engine block is observed satisfactory.

We have successfully executed hundreds of jobs. These include damaged and cracked cylinder liners, pistons, engine blocks, and major components used in heavy equipment.

We offer our services across a wide range of countries, including Singapore, Dubai, Bahrain, Bangladesh, the United Arab Emirates (UAE), Indonesia, Gambia, Iraq, Iran, Qatar, Kuwait, Malaysia, Egypt, Nigeria, Mozambique, Saudi Arabia, Oman, Turkmenistan, Jordan, and Kazakhstan.

For more information regarding cylinder liners, engine block crack repair, and crack repair of MAN main engine, please contact us at rajshahani@rapowersolutions.com or info@rapowersolutions.com or call us at +91 9582647131 or +91 9810012383.

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Over time, cast iron heads can develop cracks, warping, or other damage due to overheating, stress, or wear. That’s where our expert team steps in. With over 47 years of experience, RA Power Solutions uses advanced metal stitching (metal locking) techniques to restore structural integrity — without the risks associated with welding.

Cast Iron Cylinder Head Repair

At RA Power Solutions, we fix broken engine parts called cylinder heads. Imagine a cylinder head like a cap on a bottle- it keeps everything inside safe. Sometimes, these cylinder heads, made of strong cast iron, can get damaged. That’s where we come in! Our experts at RA Power Solutions know how to mend and make them strong again. We use special tools and skills to fix the cracks and make the cylinder head work like new. So, if your engine’s cylinder head is not feeling well, bring it to us, and we make it healthy again.

Cast Iron Head Repair

Cast Iron Cylinder Head Repair by RA Power Solutions is a service that helps fix broken or damaged cast iron heads, and engine block liners of engines. If the head of your engine is cracked, chipped, or not working properly, RA Power Solutions can help make it as good as new. They use special techniques and skilled experts to mend the cast iron head, ensuring it works well, and your engine runs smoothly. Trust RA Power Solutions for reliable and effective cast iron head repairs by metal lock and metal stitching process.

Our Repair Process Includes:

• Thorough inspection and crack detection
• Cold repair using metal stitching, preserving original metallurgy
• Surface machining and pressure testing
• Reassembly and testing for performance assurance

For more information on Cast Iron Head Repair, Cylinder Head Repair and cylinder heads please email us at rajshahani@rapowersolutions.com or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

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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.

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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-seven 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-seven 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.

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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 47 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.

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Crack Repair Process for Cast Iron, Aluminium & Bronze Components

1. Visual Inspection of the Damaged Casting

Our experienced technicians first visually inspect the damaged casting to assess the location, extent, and nature of the crack.

2. Surface Preparation

We remove paint, red oxide, and other surface coatings from the cracked area using suitable chemicals. This exposes the casting surface and allows us to perform accurate crack detection.

3. Crack Detection and Inspection

We use the following methods to identify cracks and determine their extent:

• Magnetic Particle Inspection (MPI): Our qualified technicians use high-intensity Magnaflux equipment to detect surface and near-surface cracks.
• Level 2 and Level 3 Inspection: Our in-house technicians qualified to Level 2 or Level 3 conduct and evaluate the required crack detection tests.
• Dye Penetrant Testing (DPT): We also use the conventional dye penetrant method where the component profile or material requires it.

4. Planning the Metal Stitching and Metal Locking Repair

After identifying and assessing the cracks, our experienced technicians plan the appropriate metal stitching and metal locking repair procedure. They determine the required key, lock, and stitching-pin arrangement based on the crack length, depth, component geometry, and material condition.

5. Executing the Crack Repair

Our technicians carry out the crack repair using metal stitching and metal locking with the required precision. They mechanically secure the cracked sections and restore the structural integrity of the damaged component without applying welding heat.

6. Repairing Cast Iron, Aluminium and Bronze Components

We undertake crack repairs on a wide range of cast iron, aluminium, and bronze components, including engine blocks, compressor components, pump casings, heavy machinery parts, and other damaged castings.

Our technicians remain available around the clock for emergency crack repair requirements. Some of our technicians have more than 47 years of experience in repairing engines, compressor pumps, heavy components, and severely damaged castings.

RA Power Solutions has undertaken hundreds of jobs of damaged casting repair by fixing the new casting piece in place of the damaged area.

Our success rate in repairing cracks and badly damaged castings using the metal lock and metal stitching technique is almost 100%. All crack repair jobs undertaken by us are guaranteed for satisfactory performance. The crack repair of engine components, compressors, and marine equipment can be undertaken on vessels even while sailing.

All technicians have valid Indian CDC and can board the vessel in a short time.

We have been regularly executing the repairs in Benin, Ghana, Burkina Faso, Ivory Coast, Nigeria, Mali, Liberia, Guinea, Niger, Cameroon, Equatorial Guinea, Sierra Leone, Gabon, Guinea-Bissau, Senegal, Gambia, etc.

For more queries on Aluminium Piston Crack Repair, repairing a crack in casting, the metal stitching process, crack repair techniques, and repair of a crack in cast iron casting, contact us at rajshahani@rapowersolutions.com or info@rapowersolutions.com or call us at +91 9582647131 or +91 9810012383.

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RA Power Solutions technicians visited the island and undertook the inspection as per the following details:

• Our technicians inspected the engine block/entablature of the Wärtsilä 12V32 engine.
• During the visual inspection, they found multiple cracks around the inspection window of the engine block.
• A 590 mm × 360 mm section of the entablature casting had broken away completely.
• Our qualified technicians thoroughly cleaned the affected area and removed all paint and red oxide to expose the damaged casting.
• They performed Magnetic Particle Inspection (MPI) to detect and identify all cracks in the affected area.
• Our technicians also measured the broken casting section to determine the extent of the damage and plan the repair accurately.

The details of the crack observed are as follows: –

• Our technicians identified multiple cracks ranging from 20 mm to 430 mm in length across the damaged area.
• Our technicians restored the profile of the damaged section of the Wärtsilä engine block by cutting and grinding the area to the required final dimensions of 660 mm × 396 mm.

Repairing a Damaged Wärtsilä 12V32 Engine Block When a Replacement Was Unavailable

Diesel engines are in operation all over the world in power plants, ships, heavy engineering industries, etc. The breakdown of the engine happens either due to mishandling, material defects, or poor maintenance of the engine. This results in a major breakdown, which can be devastating.

These types of accidents cause severe damage to the engine component or even injuries to the operator present in the engine room.

The concentrated heat caused by the welding process also results in the expansion and contraction of the casting, developing the stresses in the engine block/entablature.

Prior to the arrival of RA Power technicians on site, the owners of the diesel power plant explored various possibilities of repair, including repair by welding process. Our technicians explained that welding the cast-iron engine block would be difficult. The high carbon content in cast iron can burn during welding, making the repair more challenging and increasing the risk of further damage to the casting.

In some cases, the welding due to the high-temperature process also results in the hardening or rather development of more cracks. We have also experienced significant loss of the centreline of the main journal housings of the block due to stress and contraction, which is of great importance.

Repair of the Wartsila 12V32 engine block by metal stitching and metal locking process

The repair of engine block and entablature of the Wartsila engine model 12V32 was undertaken by the metal stitching and metal locking process, which is a proven cold repair method for repairing heavy cast iron casting, aluminium casting, broken engine blocks and steel cast components.

Engineers use specially designed screws, keys, and locks to repair cracks and damaged castings through the metal stitching and metal locking process.

Our technicians repaired all the cracks identified in the Wärtsilä 12V32 engine block using the metal stitching process. They also prepared and fitted a new section of casting to replace the broken portion of the engine block and securely metal-stitched it to the existing casting.

After completing the metal locking and metal stitching repairs, the team commissioned the engine and placed it under load. The engine performed satisfactorily during the load test.

RA Power Solutions completed this Wärtsilä 12V32 engine block/entablature repair in 2013, and the engine has continued to perform satisfactorily since the repair.

The repair enabled the client to avoid purchasing a replacement engine block, resulting in substantial cost savings. It also significantly reduced downtime, which was particularly important because the client operates a power-generation facility serving islands in the Maldives.

RA Power has a dedicated team of experienced technicians headed by an engineer with over 47 years of experience in the repair of cracks in cast iron, aluminium cast steel, and steel casting by metal stitching and metal locking.

Global Onsite Cast Iron Crack Repair Services

All our technicians have valid CDC and can fly to any destination on short notice. The portable, lightweight pneumatic tools are carried by them as accompanied baggage. We have been regularly executing the repairs in Madagascar, Oman, Qatar, Philippines, Bahrain, Sri Lanka, Bangladesh, Myanmar, Turkey, Nigeria, Greece, Saudi Arabia, UK, Dubai, Malta, Cyprus, Singapore, Malaysia, Colombia, Indonesia, Hong Kong, Spain, Netherlands, Dubai, Portugal, Estonia, Morocco, Belgium, Vietnam, Canada.

For more information on repair cast iron, cast iron stitching, cast iron engine repair, cast iron crack repair, cold metal stitching, cast iron engine block metal lock, broken engine block, and metal surgery contact us at rajshahani@rapowersolutions.com or info@rapowersolutions.com or call us at +91 9582647131 or +91 9810012383.

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