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:

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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.

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 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.

FAQs:

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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.

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 has proven to be very successful and can save 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 with Wartsila 12V32 and Wartsila 18V32 engines, reported a serious accident in one of their Wartsila 12V32 diesel generating sets. The team of engineers of RA Power Solutions conducted the inspection, and the following observations were made: –

The accident occurred after the connecting rod bearing failed. The connecting rod then struck both sides of the engine block and caused extensive damage. Our technicians performed Magnetic Particle Inspection (MPI) and Dye Penetrant Testing (DPT) to identify the damage and detected multiple cracks ranging from 3 to 18 inches in length.

Repair Procedure for the Wärtsilä Engine Block

• Our technicians decided to cut away the damaged and cracked section of the engine block and restore the area to a precise, controlled profile for the repair.
• Our technicians removed damaged sections measuring 24 × 39 inches and 13 × 26 inches from both sides of the engine block.
• Our technicians conducted an MPI test on the crankcase to confirm that no cracks remained in the repaired area.
• Our technicians prepared a wooden pattern onsite based on the dimensions and profile of the damaged section removed from the engine block. The foundry then manufactured the new casting strictly according to the pattern. Afterward, our team carried out the necessary machining in-house to achieve the required dimensions and profile.
• Our technicians positioned the new casting on the engine block and securely attached it using the metal locking and metal stitching process.
• Our technicians ground the outer surface and precisely matched it with the surrounding parent casting, restoring the original profile and surface continuity.
• 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-Seven 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 After Wärtsilä 12V32 Engine Block Repair

RA Power Solutions followed up with the client after completing the Wärtsilä 12V32 engine block repair. The client confirmed that the engine had completed more than 6,300 running hours since the repair, with no leakage or operational problems 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 47 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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