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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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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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.

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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.

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 over forty-seven 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 over forty-seven 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.

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We have observed that, despite strictly following the maintenance schedule provided in the manufacturer’s manual, serious accidents still occur. These incidents often result in the casing of engines, compressors, or heavy engineering equipment breaking into pieces or developing multiple cracks.

RA Power Solutions recommended repair of damaged cast iron casting, Aluminium bronze components by metal lock and metal stitching process, having the following advantages:

• The main advantage of repairing of damaged or cracked engine block by the metal lock and metal stitching process is that it is a cold method of repair, and no heat is generated.
• No distortion in the profile or shape of the engine block or casing takes place. This is a common issue when crack repairs are carried out by welding, but our method avoids it.
• Metal lock and metal stitching process of crack repair can be performed on-site, avoiding the high cost associated with the disassembly of the equipment and transporting it to the designated workshop for repair. Metal stitching can be done in a limited space.
• It is proven that the crack repair of engine blocks, cast iron castings, and aluminium and bronze components restores their original strength. It is also successful for water-tight and gas-tight repairs.
• We have experienced that engine blocks repaired by the metal lock and metal stitching process do not lose their profile or shape. In most cases, engine blocks do not require any machining.

RA Power Solutions has successfully executed the repair of more than three thousand cracked, damaged, and rejected engine blocks, compressor casings, and heavy equipment across the globe. Our expertise has saved millions of dollars for the shipping and general industries.
We strongly recommend the repair of cracked or damaged components by the metal lock and metal stitching process.

The applications for the repair of cracks by metal stitching and the metal locking process are many and cover a broad range as follows:

• Repair of heavy equipment, large earth-moving machinery, and mining equipment.
• Repair of Alternator casing, turbine, Turbocharger, cylinder head, and all rotating equipment.
• Repair of cracked or damaged engine block metal locking.
• Bed Plate (crankcase repair)

RA Power Solutions has also undertaken successful crack repair in aluminium pistons and heavy-duty cylinder liners as a temporary measure. We provide guaranteed repair of all heavy engineering components manufactured from cast iron, aluminium, or bronze.

At RA Power, we have been regularly undertaking the 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
• Wärtsilä
• 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, Singapore, Dubai, etc

For more information on Engine Block Stitching, Turbine casing crack repair on site, metal locking, cast iron engine block metal lock, and engine block metal locking, contact us at rajshahani@rapowersolutions.com, info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

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The post Metal Stitching & Metal Locking Of Engine Block appeared first on Metal Stitching and Metal Locking Services | RA Power Solutions.

RA Power Solutions undertakes aluminium crack repair by metal stitching, metal locking and metal surgery process which is a cold process of repair of cracks of aluminium components, cast iron components, and cast steel.

Generally, all the heavy components manufactured out of aluminium casting can be repaired by metal stitching, metal locking and metal surgery.

Cracked Aluminium Cylinder Head Repair

It is not possible to undertake repair of cracks & damage to cylinder head, cylinder liner, and components manufactured of aluminium or cast iron by welding process due to the generation of heat.

A few of these are described below:-

• Crack repair of aluminium cast pistons.
• Crack repair of the engine block manufactured out of aluminium alloys.
• Damaged or cracked pump casings, turbocharger casings, and turbine casings can be repaired by the metal locking and stitching process.
• Repair of cylinder liners and cylinder heads manufactured out of cast iron or aluminium.
• Aluminium Piston Crack Repair.

In order to undertake aluminium crack repair or repair of damaged aluminium casting, cast iron or steel casting components.

We follow the procedure given below:-

• Crack detection.
• It is important that prior to starting the process of crack repair, the cracks are properly identified, and the location is marked. The cracks are checked by the following methods.
• Visual Inspection
• Dye penetrant test of cracks in the damaged area.
• Crack detection by MPI using the high-intensity magnaflox torch.
• Pressure Testing

We strongly recommend that in case of red oxide or paint on the surface of a damaged component, it should be thoroughly removed.

• Aluminium Crack Repair by Metal Stitching and Metal Locking process

After the location of the crack or cracks is identified, the cracks are repaired by metal stitching and metal locking process.

We use the following special pins and locks for metal locking:-

• Standard threaded pins – They are straight-thread L-Series pins. They are designed to seal by interference fit after threads. The threaded pins exert spreading pressure for sealing, seat retention, and crack removal.
• Spiral thread hooks for radial drawing force are used, which creates structural integrity, seals leaks, and also prevents crack propagation.

The repair of cracks in aluminium cast components requires special tools and experience as the aluminium casting cuts easier than the cast iron, RA Power Solutions regularly undertakes repair of aluminium cast iron and steel casting components and has executed repairs successfully in countries like Dubai, Greece, Maldives, Malaysia, Singapore, Madagascar, Nigeria, South America, UAE, Germany, Monaco, Qatar, Sri Lanka, Bangladesh, Italy, Spain, Czech Republic, UK, Philippines, Singapore etc.

For more information on Piston Repair by Metal Locking, Turbine casing crack repair on-site, Cracked Aluminium Cylinder Head Repair, and Cylinder liner head repair, contact rajshahani@rapowersolutions.com or info@rapowersolutions.com or call us at +91 9582647131 or +91 9810012383.

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

This process of Onsite Crack Repair Has replaced the old and conventional method of crack repair by welding. Crack repair by metal stitching and locking is becoming popular worldwide.

The main advantages are as follows:-

• In this time of recession, get your equipment repaired successfully on site and avoid replacement.
• In 99% of cases of accidents, crack repair by metal stitching has proved to be successful.
• Can you afford a long breakdown in your plant? No, get your equipment back in service in a few hours.
• A fantastic solution and technological innovation for crack repair without disassembly of the equipment. Repair is possible on-site, metal surgery, even on ships and on the high seas, or at remote heavy engineering plants.
• In most cases, no machining is required, as no heat is generated.
• A pressure-tight seal can be achieved.
• The metal lock and metal stitching process is recognised by the classification societies.

Expertise available with RA Power Solutions for Forty-Seven Years:

You cannot trust the repair of your expensive equipment to a company that is not experienced. RA Power Solutions, with 47 years of experience, has technicians who have spent their lifetime successfully repairing the engine and heavy machinery components that have been seriously damaged. The successful repair of cracks and damaged components needs proper planning and execution.

We have been regularly repairing the cracked components of the most popular engine makes like Wartsila, Daihatsu, Mirrless Blackstone, Yanmar, Allen, MAK, MAN, B&W, Sulzer, Caterpillar, etc.

The consumables used by us to undertake the repair by the metal stitching process are of high quality and proven for their satisfactory performance. The effective and proven alloy of MN211 AND MN 555 is used for undertaking the repair by metal stitching.

RA Power Solutions has successfully executed thousands of crack repair jobs all over the world. The cost of repair offered by us is the lowest in the market.

For more information on onsite metal surgery, engine block metal locking, and turbine casing crack repair onsite contact us at rajshahani@rapowersolutions.com or info@rapowersolutions.com or call us at +91 9582647131 or +91 9810012383.

The post Onsite Crack Repair | Metal Lock | Metal Surgery appeared first on Metal Stitching and Metal Locking Services | RA Power Solutions.

RA Power Solutions as a repair company has tried the process of cast iron block repair by metal stitching, metal locking and welding. We have observed that the repair of damage casting and repair cracks by metal stitching, metal lock and metal surgery is most successful in comparison to welding.

The following are the advantages of the welding process of repair:

• The metal stitching and metal locking are a cold repair of the crack. There is no stress developed as no heat is generated.
• In most cases, no dismantling of equipment is required.
• In normal situations, access to the pneumatic tools is only required.
• Metal lock/metal stitching is a cold method. No loss of alignment or profile is observed. Hence, in most cases, no machining is required.
• The repaired area by the metal lock and the metal stitching process is liquid and gas-tight.
• With time, it has proved to be almost a permanent repair.

The brief process of metal stitching/metal locking for crack repair in aluminium, bronze, and cast iron components is as follows:

To make the crack repair or repair of damaged casting successful by metal stitching and metal lock process, the damaged area must be thoroughly checked for the length, location, and number of cracks, preferably by MPI equipment.

We suggest that a minimum of level two or level three qualified technicians should undertake the crack detection inspection by the MPI process. In case of non-availability of MPI equipment, the crack detection test by dye penetrant test can also be undertaken. It is of utmost importance that no crack should go unidentified, which, in case left without metal stitching and a metal lock. It can elaborate further and cause serious damage to the component and the equipment in totality.

The cracks and the damaged portion should be identified and marked clearly.

The cracked metal is replaced with special metal stitching pins, which are placed by drilling and tapping.

To pull the sides of the crack together, specially designed metal stitching pins are inserted. This results in the continuous formation of a row of interlocking stitching pins. In turn, this develops a strong and pressure-tight repair. The master locks are installed across the joint line bya drilling process to give additional strength.

For all your requirements of Crack Repair by metal stitching, 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 BY METAL STITCHING INSTEAD OF WELDING | 47 YEARS OF EXPERIENCE appeared first on Metal Stitching and Metal Locking Services | RA Power Solutions.

RA Power Solutions Pvt. Ltd. undertakes the repair of cracks, the repair of damaged casting, and damaged engine blocks made out of cast iron or aluminium. All the parts that are manufactured out of cast iron and aluminium can be successfully repaired for cracks or damage due to accidents by the metal lock and metal stitching process, which is a cold process as no heat is generated.

The following are the advantages of undertaking crack repair in cast iron and aluminium components by Metal Locking and Metal Stitching

• There is no need to remove the engine block and send it to the workshop. The crack repair and damage casting repair can be undertaken onsite.
• We depute our team of engineers with portable equipment and consumables to the site to undertake the crack repair and repair of damaged engine block casting by metal lock, metal surgery and metal stitching.
• The welding process for repairing cracks is now outdated. It creates stresses and, in most cases, requires machining after the repairs.
• We use high-grade consumables such as metal locks and keys imported from the UK. All crack repairs are executed with a guarantee.
• The planning of execution of the repair is prepared by the senior engineer and executed by our technicians. Our senior technicians have hands-on experience of more than 47 years.
• We extend crack repair services all over the world to shipping companies and industries.
• All our technicians engaged in crack repair by metal lock and metal stitching process have valid CDC certificates and can travel to any part of the world on short notice.

For more information on cast iron block repair, engine block stitching, fixing cracked engine blocks, onsite repair of engine block, engine block crack repair, cracked engine block repair, cracked engine block repair stitching, and repair of damage casting contact us at rajshahani@rapowersolutions.com or info@rapowersolutions.com or call us at +91 9582647131, or +91 9810012383.

The post CRACK REPAIR IN ENGINE BLOCK | REPAIR OF DAMAGE CASTING appeared first on Metal Stitching and Metal Locking Services | RA Power Solutions.

In the case of large and heavy cast iron or casting components like engine blocks, turbo casings, gearboxes, forging pillars, etc. It is not necessary to replace such large, heavy cast iron and expensive components. These components, after initial inspection, can be successfully repaired.

RA Power Solutions, having experience of four decades, undertakes the repair of the following types of cracks or serious damage to casting by the metal lock and metal stitching process.

• Cast Iron Crack Repair, cast steel, and aluminium cast components, irrespective of their length and application, can be repaired by metal stitching.
• In case the casting is damaged into pieces, the damaged portion of the large cast iron components is cut, and the new casting piece is assembled again with a metal lock and a metal stitching process.

Cold Metal Stitching Cast Iron

Repair of cracks and damaged casting by the cold process of metal stitching & metal locking is the most successful way of repair. The metal stitching and metal locking process of crack repair does not develop heat, as it is a cold process. No alignment or profile is lost, hence in most cases there is no requirement for machining.

We are the leaders and specialize in executing the repair of cracks and repair of damage to casting of any size by metal lock or metal stitching. With our experience, we have learnt that crack repair by welding does not guarantee successful repair in most cases, and it needs correction of the profile in most cases due to loss of alignment.

RA Power Solutions has been serving large diesel power plants, heavy industries, and shipping companies, and has successfully executed thousands of jobs using by metal lock process, which has been damaged. The possibility of repair of damage in casting or repair in casting onsite makes metal locking and metal stitching the most popular technique.

We have a team of experienced technicians who have a record of successfully executing crack repairs. All the technicians are factory-trained and hold valid CDC. They can fly to any part of the world, whether the assignment is on land or in high sea. With the help of portable, lightweight, pneumatic tools and metal lock keys and locks, the repairs are executed in a short duration.

It is also observed that due to the failure of any component, the threads also get damaged. The damaged threads are repaired by rethreading, recoiling, and with the combination of metal stitching and metal lock. This process of thread repair has been followed again by us at different sites all over the world, and it has proved to be of great success in saving the parts.

The repair of cracks in casting or damaged components by metal lock and metal stitching is guaranteed for satisfactory performance by RA Power Solutions. The cost of crack repair undertaken is negligible in comparison to the replacement cost with the new component, apart from the difficulties involved in procurement dispatch assembly of the new component.

For all your requirements of crack repair in heavy equipment, contact us for an initial inspection and suggestions for successful salvaging of damaged components.

RA Power Solutions has a team of technicians with 45 years of experience in undertaking the repair of cracks and badly damaged casting by metal locking & metal stitching.

For more information on Crack Repair of Cast Iron, cold stitching cast iron, metal lock, cold cast iron repair, metal stitching, cold metal stitching, and engine block repair, call us at +91 9582647131 or +91 9810012383, and Email id rajshahani@rapowersolutions.com, or info@rapowersolutions.com.

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