Most people say, “Time to scrap and replace,” when a heavy machine casting breaks, a turbine housing splits, or a cast iron engine block cracks. But what if you could fix that broken piece of metal without welding, bending it, or replacing the whole thing? That’s where metal stitching (sometimes called metalocking) comes in. It might save you a lot of money.

What Metal Stitching or Metalocking Actually Means

Metal stitching, which is also known as cold metal mending or metalocking, is a tried-and-true way to fix cast iron, steel, aluminum, or other comparable cast parts that are cracked or damaged. This method doesn’t involve welding, which melts metal, adds heat, and can cause distortion. Instead, it employs specially designed metal “keys” or “locks” and stitching pins to mechanically pull the broken sections back together, sealing the fracture and restoring strength.

This procedure goes back to the 1930s, when it was first used to fix oil-field castings where welding with an open flame was dangerous.

How the Process Works (Step by Step)

1. Drilling or stop-holes: Technicians drill holes at the extremities of the crack to keep it from spreading.

2. Making a slot or aperture: A pattern of holes is made along the crack, usually at right angles, and then connected to provide a slot that fits the shape of the metal keys.

3. Putting in Metal Keys and Locks: Special alloy keys are put into those slots and hammered to make a strong bond between the two metals.

4. Stitching with Pins or Studs: Along the fracture line, holes are drilled and threaded, and then interlocking stitching pins or studs are put in. These close the crack and make the joint watertight.

5. Finishing: After the region is secured, it is ground flush, sometimes machined, and finished to bring back its original shape, alignment, and surface integrity.

Why does it beat welding or replacing it by a long shot

No heat means no distortion:

Since there is no welding or heat, the old casting won’t warp, have any residual tension, or modify its metal structure, which could make it weaker.

Original geometry preserved:

Because the metal isn’t melted or changed too much, the repaired part usually keeps its original alignment, size, and surface finish, which means that re-machining is less likely to be needed.

Strong, leak-proof repair:

The metal stitching and locking make the repair as strong as (or sometimes stronger than) the original casting. Repairs are typically gas-tight or liquid-tight, which is beneficial for engine blocks, pump housings, turbine casings, and other things.

Quick and onsite:

Repairs can typically be done on-site, so you don’t have to take apart big machines or send parts to a workshop. That means a lot less downtime and big savings over replacing parts.

Cost-effective:

Stitching or locking repairs typically cost a lot less than getting a new casting, and you also eliminate the costs of downtime, transportation, and installation.

Where This Method Can Be Used

Metal stitching works across a ton of industrial components:

• Engine blocks, cylinder heads, crankcases
  
• Turbine and compressor housings
  
• Pump & gearbox casings
  
• Machine bedplates, press structures, forging frames
  

Basically, if it’s cast iron, cast steel, or cast aluminum—and cracked—this method might save it. A ship’s engine block may crack, a power plant’s pump casing may break, or a foundry’s press frame may fail.

Why Metal Stitching Makes Even More Sense in 2025

Industries today face massive downtime costs. Welding large castings often leads to distortion, micro-cracks, weakened structure, and costly re-machining. Cold metal stitching avoids all of that. It’s now one of the most preferred emergency repair and maintenance solutions in marine, power, manufacturing, and heavy equipment industries because it’s quick, eco-friendly, and keeps expensive parts in use for years.

A Real-World Win

Imagine a diesel engine block with a massive crack. Most people would write it off as scrap. But with cold stitching — drilling, inserting keys, sealing with pins, pressure testing, and machining — the block comes back as strong as new. Many marine vessels, power plants, and factories around the globe have saved valuable components this way.

When Metal Stitching Might Not Fit the Situation

It’s not magic — a few things can limit it:

• If the casting is shattered into many pieces
  
• If the damage is too extensive
  
• If unskilled technicians attempt the repair
  
• If the component will operate under extreme stress, needing deeper analysis
  

Quality of workmanship matters a lot in this process.

Don’t rush to scrap or weld a cracked engine block, turbine casing, or any expensive casting. Cold-metal stitching is a proven, cost-saving, distortion-free, and long-term solution trusted worldwide. It’s efficient, affordable, and gives old components a new life — exactly why it should be part of every maintenance strategy.

For any information regarding metalock, metal stitching, engine block repair, please email us at rajshahani@rapowersolutions.com, info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

FAQs

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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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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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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:

The post Cast Iron Repair | Aluminum | Bronze Crack Repair | Metal Lock | Metal Stitching appeared first on Metal Stitching and Metal Locking Services | RA Power Solutions.

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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The problem of heavy leakage of oil was observed from the rear centre fuse casing. Our technicians visited the site and carried out the following jobs.

Action taken for repair of the damaged centre fuse, rear casing machine block by metal locking, metal stitching and metal surgery

• As mentioned above, heavy leakage of oil was observed from the casing.
• To check the cracks and weaknesses in the casting, the paint and red oxide were completely removed by a buffing process.
• Our engineer, qualified to do the MPI test, undertook the crack detection test of the completely damaged casing with a high-intensity Magnaflux torch and equipment which is designed by Magnaflux USA to detect even minor cracks which otherwise cannot be seen by the naked eye.
• The MPI test was done repeatedly in a critical area.
• Due to the complex profile, the crack detection was done even by the basic procedure of the dye penetrant method. A large portion of weak casting was observed, and multiple cracks of different lengths and profiles were also observed.
• The repair of the centre fuse rear casing machine block was undertaken by the metal locking and metal stitching process. The special alloy self-merging keys & locks were used to repair the cracks.
• The polishing by the special equipment was undertaken, and the original shape & profile of the casing was given.
• In order to ensure that there is no leakage of oil, a special chemical imported from our principles based in the UK was applied as per the procedure.

The Plant was recommissioned, and no leakage of oil was observed.

RA Power Solutions, with forty-five years of experience, undertakes the guarantee for all the jobs of crack repair and repair of damaged casting undertaken by us.

We have engineers with forty-five years of experience dedicated only to crack repair and repair of damaged casting. We specialize in the repair of heavy equipment used in power plants, oil & natural gas rigs and heavy engineering equipment. These services are offered all over the world.
All our technicians have a valid seaman book, and US VISA and can fly to any destination of the world in a short time.

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, 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 information, Metal Stitching and Metal Surgery process, crack casting repairing, Turbine casing crack repair on site, and crack repair damaged casting rectification Contact us at rajshahani@rapowersolutions.com, info@rapowersolutions.com or call us at +91 9582647131 or +91 9810012383.

FAQs:

The post Metal Locking | Metal Stitching | Crack Repair Damaged Casting Rectification | Ra Power Solutions appeared first on Metal Stitching and Metal Locking Services | RA Power Solutions.

It was reported that due to an accident, the block of the CO2 compressor was badly damaged and required repair.

Action was taken by RA Power Solutions for the repair of CO2 compressor Block:

Considering the seriousness of the accident, a team of three technicians was deputed. On visual inspection, it was observed that the distance piece housing of the CO2 compressor was badly damaged into pieces. Multiple cracks of different profiles and lengths were also observed on the block of the compressor, the photograph is given below.

Action is Taken for the Metal Stitching & Repair of the Compressor Block

• The damaged area was thoroughly cleaned by the use of special chemicals.
• The paint and red oxide were completely removed.
• The MPI of the damaged area was undertaken by a qualified engineer with a high-intensity magnafux torch.
• Multiple cracks measuring in length ranging from 160 mm to 320 mm were observed.
• The large portion measuring about 8 inches by 6 inches was completely damaged, hence it was decided to completely remove the damaged portion and cast a new piece.
• The area of the housing which was not accessible by the MPI equipment. It was subject to dye penetrant test in order to check the cracks.
• The new piece of casting was placed on the main casing and was metal stitched, as can be seen in the photograph below. The photograph of the new casing piece is also given.
• The remaining cracks were repaired by a metal locking process.
• We used L20 locks and Cast Master pins with a length of 25 mm and a diameter of 8 mm for the metal locking process. The casing had serious damage and multiple cracks.

RA Power Solutions is the only company with forty-five years of experience. The Major repair is by metal locking and metal stitching process.

All our technicians have a valid seaman book, and US VISA . They can fly to any destination in the world in a short time.

Globally Business: RA Power Solutions

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, Repair Of Damaged Compressor Block, 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.

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:

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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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