Crack Repair In Cast Iron | Aluminium | Cast Steel

RA Power Solutions has repaired cracks and damaged engine blocks in a simple process. This achievement of repairing engine blocks, turbine casings, cylinder heads, and major parts of high-capacity engines is possible because of our experience in undertaking repairs of damaged and cracked casting by the metal lock and metal stitching process.

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.