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.

FAQs:

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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.

FAQs:

The post Crack Repair Of Aluminium | Bronze And Cast Iron Component By Metal Lock & Metal Stitching appeared first on Metal Stitching and Metal Locking Services | RA Power Solutions.

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.

FAQs:

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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 45 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.

FAQs:

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

• Inspection of engine block/entablature of Wartsila engine, model 12V32.
• On a visual inspection by our technicians, it was observed that the engine block developed multiple cracks near the inspection window.
• A piece measuring 590 mm X 360 mm was damaged from the entablature casting and came out.
• Our qualified technicians cleaned the surface area thoroughly, even the paint and the red oxide were removed.
• The MPI was done for crack detection and all the cracks were clearly identified.
• The measurement of broken casting was also taken.

The details of the crack observed are as follows:-

• Multiple cracks having a length ranging from 20 mm to 430 mm were observed.
• The discipline profile of the damaged portion of the Wartsila engine block was given by cutting and grinding the final dimensions which were observed as 660 mm X 396 mm.

Non-availability of Wartsila 12V32 engine block

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 the difficulty in repairing the engine block, which is manufactured out of cast iron by the welding process. Cast iron contains a high level of carbon, which burns when the repair of casting is undertaken by a welding process.

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 that due to stress and contraction, there is a significant loss of the centreline of the main journal housings of the block, which is of great importance.

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

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

Different types of specially designed screws and locks are used in crack and damaged casting repair in the metal stitching and metal locking process. The multiple cracks as per the details mentioned above were repaired by the metal stitching process. The damaged area of the Broken Engine Block was fitted with a new piece of casting and was metal stitched. The engine was put on load after the repairs by metal lock and metal stitching process and performance was observed as satisfactory. This job of repairing of Wartsila engine block/ entablature of 12V32 was executed in the Year 2013 and since then it has been performing satisfactorily. The client has not only saved a considerable amount by avoiding the purchase of a new engine block but also saved on downtime as they are in the business of power generation for the islands based in the Maldives.

RA Power has a dedicated team of experienced technicians headed by an engineer with more than 44 years of experience in the repair of cracks in cast iron, aluminium cast steel, and steel casting by metal stitching and metal locking.

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.

This blog is written by Mr. Raj Shahani (Managing Director of RA Power Solutions India Pvt. Ltd.).

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 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.

The post Cast Iron Repair | Broken Engine Block by Metal Stitching appeared first on Metal Stitching and Metal Locking Services | RA Power Solutions.

The cast iron engine block is difficult to weld as it is very brittle. The repair of the cracked engine block by metal lock/metal stitching/metal surgery is proven to be of great success and can result in saving a huge amount, as one can avoid buying a new engine block.

Repair of Wartsila 12V32 Engine Block

One of our clients running a Diesel power plant in South America having 47 numbers of Wartsila 12V32 and Wartsila 18V32 engines reported a serious accident in one of their diesel generating sets of Wartsila 12V32 model. The team of engineers of RA Power Solutions conducted the inspection, and the following observations were made:-

The accident took place due to the failure of the connecting rod bearing. The connecting rod hit the engine block from both sides and damaged the block. On undertaking the crack detection test by MPI and dye-penetrant test, multiple cracks having lengths measuring from 3 inches to 18 inches were observed.

The following action was taken to repair the Wartsila Engine block:-

• It was decided to cut the damaged and cracked portion of the engine block and give it a disciplined profile.
• The portion measuring 24 inches by 39 inches and 13 inches by 26 inches on both sides of the engine block was removed.
• The MPI test was conducted to ensure that no cracked areas remain in the crankcase.
• The wooden pattern was prepared onsite as per the damaged and removed casting portion of the engine block. The new casting was manufactured strictly as per the wooden pattern dimensions and profile, and the necessary machining was done in-house.
• The new casting was placed on the engine block and was attached by a metal locking and metal stitching process by our technicians.
• The outer surface was ground and matched with the parent casting.
• The repair of the engine block by replacing the damaged casting and fixing it with a metal lock and metal stitching proved to be successful.
• Our technicians also ensured that no leakage of lubricating oil took place.

RA Power Solutions Pvt. Ltd. has been extending the Crack Repair In Cast Iron and damage casting services for the last forty-five years and has the technicians and necessary portable tooling available to undertake the onsite repairs. The repairs on board the vessel and while sailing the vessel are also possible. We have technicians possessing Indian CDC, and it is possible to depute them on short notice.

Follow-up by RA Power Solutions after repair of Wartsila engine 12V32 was done, and it was communicated that the Engine had completed more than 6300 running hours after repair. No leakages and no problems in the operation have been reported.

The company has saved an enormous amount by avoiding the purchase of a new engine block from Wartsila.

For all your requirements of crack repair or repair of damage casting of cast iron, aluminium, or steel casting, you may contact rajshahani@rapowersolutions.com, info@rapowersolutions.com, or call us at +91-9582647131 or +91 9810012383.

The post Crack Repair In Cast Iron | Aluminium | Cast Steel appeared first on Metal Stitching and Metal Locking Services | RA Power Solutions.

The cost of replacing parts in case of damage is exorbitant. Non-availability or delay in arranging the parts is also a major issue. The repair of damaged parts by replacing them with new casting or the repair of cracks by metal stitching and metal locking is the fastest and most economical technology of repair.

The advantages of crack repair by metal stitching and metal locking are many, a few of them are listed below:

• The crack repair and repair of damaged casting can be done onsite. In most cases, there is no requirement to dismantle the equipment.
• Cold process and no heat is generated. Hence, there is no deformation or loss of the original profile. In most cases, no machining is required after repairs by metal stitching and the metal locking process.
• Crack repair by metal stitching and metal locking is possible in the area that is liquid and gas-tight.

We undertake this kind of repair with a guarantee. The crack repair and repair of damaged casting by metal locking and metal stitching is permanent, and no further process or treatment is required.

RA Power has a team of metal stitching engineers having experience of 45 years in handling complicated and damaged components. We provide repair services all over the world.

For more information on metal stitching service providers and cold metal stitching, cold stitching cast iron, cold stitching, and cast iron head repair, email us at rajshahani@rapowersolutions.com, or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

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