Metal Stitching | Metal Locking | Crack Repair | Metal Surgery

RA Power Solutions having more than forty years of experience in field of repair and maintenance of high capacity engines, understands the importance of the parts.

In case of damage of engine components or crack, RA Power Solutions undertakes repair onsite by metal stitching or metal locking process. We are considered to be the leaders in this field as we use the master lock, master piece, keys and consumable of high quality imported from UK. Our technicians are highly experienced. Crack repair and repair of damaged casting components can also be executed while sailing of the Vessel.

Replacement of Broken casting by new one- metal stitching
Replacement of Broken Casting by New one- Metal Stitching
Inspection window reapir by metal lock
Inspection Window Repair by Metal Lock

Following is the process of metal locking, metal stitching and advantages.

Process of Metal Locking, Metal Stitching:

The Metal Stitching process is accepted as the method of repairing all cracked, broken and damaged casting in cast iron, aluminium and steel.

metal stitching of broken casting
Metal Stitching of Broken Casting
Repair of Damaged Window of engine block
Repair of Damaged Window of engine block

 

 

 

 

 

 

 

 

 

The Stitching Process
1. At first visible and invisible cracks are identified.
2. The parts are clamped together to bring the parts in original position.
3. A rectangular hole is made across the fractured portion.
4. This hole is made by drilling and chipping.
5. The Master lock, large rectangular key of special metal is inserted into the hole.
6. Locking Pins are inserted alongside the master lock to provide a tight and secured master lock.
7. A length of metal stitching keys are inserted on the sides of the master lock to prevent the locking pins to fall out when the casting is subjected to high vibrations.

Advantage of Metal Stitching
1. No heat stress are induced
2. No Distortion occurs
3. In many Instances machining is not required
4. Invaluable in emergency situations
5. Reduces downtime
6. Gas/ Liquid proof repair

metal Stitchining of Cylinder Head
Metal Stitching of Cylinder Head

For more information, please email us on info@rapowersolutions.com or call us on +91-9582647131

repaire of Crack measuring 1400mm x 1140 mm
Repair of Crack Measuring 1400mm x 1140 mm
Damged engine repair by metal locking process
Damaged Engine Repair by Metal Locking Process

 

RA Power Solutions having more than forty years of experience in field of repair and maintenance of high capacity engines, understands the importance of the parts. In case of damage of engine components or crack, RA Power Solutions undertakes repair onsite by metal stitching or metal locking process. We are considered to be the leaders … Continue reading “Metal Stitching | Metal Locking | Crack Repair | Metal Surgery”

Metal Locking and Metal Stitching by RA Power Solutions, India

Damaged engine parts, construction equipment and all mechanical equipments can be repaired successfully by metal locking and metal stitching process in case of crack or extensive damage of casting due to accident.

The repair of crack or damage casting by using traditional welding method is not successful for repair of cast iron and alloy cast metal components.

RA Power Solutions has expert team of technicians who are trained to execute repair of crack and repair of damage casting of large equipments by metal stitching and metal locking process.

Broken Area of Generator
Damaged Area of Engine Block Measuring 14 inches X 12 inches
Metal Stitching of New Casting Piece in Broken Area
New Piece of Casting Metal Stitched

The repair of crack by metal lock and metal stitching process has following advantage:

I) In case of crack or damaged component, there is no need of sending it to designated workshop. Our technicians visit the site and undertake repair of crack by metal locking and metal stitching process.

II) Metal lock and metal stitching is a proven method of repair of crack. It’s is a permanent solution, cold process of crack repair and no heat is generated as in case of welding.

III) In case large portion of casting is damaged it is possible to replace it with the new casting having same design, profile and metallurgical properties by metal stitching and metal locking.

We provide services of crack repair and repair of damage casting for last 4 decades all over the world. We are cost effective and execute the repairs with guarantee.

Broken Engine of Wartsila Diesel Engine
Damaged Inspection Window of Wartsila Crankcase
Engine Block of Wartisla After Metal Stitching Process
Inspection Window of Crankcase under Repair by Metal Stitching/Metal Locking

Only company offers metal stitching and metal locking services while vessel is sailing.

Contact Us for more information.

 

Damaged engine parts, construction equipment and all mechanical equipments can be repaired successfully by metal locking and metal stitching process in case of crack or extensive damage of casting due to accident. The repair of crack or damage casting by using traditional welding method is not successful for repair of cast iron and alloy cast … Continue reading “Metal Locking and Metal Stitching by RA Power Solutions, India”

Metal Stitching

Complete Piece Replaced by New Casting (Metal Stitching)
Complete Piece Replaced by New Casting (Metal Stitching)

Crack in cast iron engine components is developed due to stress or accident. It is not always financially feasible to replace the engine components which develop cracks like engine block, cylinder head, cylinder liner, turbo charger casing and other parts. The delivery time and logistics arrangement also take time resulting to the delay in re-commissioning of engine.

RA Power Solutions undertakes repair of crack or broken components by metal stitching and metal locking process. This is a cold process which is followed for the repair of crack. No heat is generated and no stresses are developed. In metal stitching and metal locking process of repair of crack keys and locks of special alloys are used.

Special Keys Used in Metal Stitching
Special Keys Used in Metal Stitching

We have technicians with over 40 years of experience in repair of broken casting and cracks. RA Power Solutions is the only company which can undertake repair of broken casting and crack by metal stitching and metal locking process on board a vessel while it is sailing. All our technicians undertaking metal stitching and metal locking repairs have valid seaman book. We have successfully undertaken repair of cracks and broken casting of following engines which are performing satisfactory.

Wartsila , Daihatsu , Caterpillar , MAN B&W, MAK , Sulzer , Bergen , Detroit Diesel , Stork Werkspoor , Pielstick , Deutz , Yanmar , MTU , Cummins , Nohab Polar , Mirrlees Blackstone, Caterpillar , Mitsubishi , Yanmar , Daihatsu and many more.

Metal Stitching by Using Broken Pieces of Engine Block
Metal Stitching by Using Broken Pieces of Engine Block
Cracked Cylinder Liner
               Cracked Cylinder Liner

Crack in cast iron engine components is developed due to stress or accident. It is not always financially feasible to replace the engine components which develop cracks like engine block, cylinder head, cylinder liner, turbo charger casing and other parts. The delivery time and logistics arrangement also take time resulting to the delay in re-commissioning … Continue reading “Metal Stitching”

Metal Stitching and Metal Locking Company in India

RA Power Solutions undertakes crack repair and replaces castings broken into pieces due to accident by metal stitching and metal locking process.

Metal Locking and Metal Stitching Company in India
Metal Locking and Metal Stitching Company in India

We have team of dedicated, trained and experienced technicians undertaking crack repairs of marine engines, compressors, plant machinery and heavy castings by metal stitching and metal locking process which is a proven method of crack repair. In case of metal locking and metal stitching no heat is generated as it is a cold process.

Companies prefer to get the crack repair and replacement of large size of castings which are damaged by metal surgery, metal locking and metal stitching process.

Broken Area of Engine Block
Broken Area of Engine Block
Repair of Broken Engine Block is in Progress
Repair of Broken Engine Block is in Progress

 

 

 

 

 

 

 

This process of crack repair in most of the cases does not require disassembly of the equipment as the crack repair by metal locking and metal stitching process is executed onsite.

Metal Stitching and Metal Locking of Broken Engine Block
Metal Stitching and Metal Locking of Broken Engine Block
Metal Locks and Keys are Inserted to Repair Broken Entablature
Metal Locks and Keys are Inserted to Repair Broken Entablature

 

 

 

 

 

 

 

RA Power Solutions have portable, light weight equipments and technicians travel  to any site or plant in India and all over the world.

RA Power Solutions is the only company in India which has more than 37 yrs of experience in successfully executing crack repair by metal surgery,metal lock and metal stitching process.

Repair of Engine Block by Metal Surgery Process
Repair of Engine Block by Metal Surgery Process
Repair of Crack Steel Casting is in Final Stage
Repair of Crack Steel Casting is in Final Stage

 

 

 

 

 

 

Most of the leading companies based in India and all over the world are regularly availing our services for crack repair and repair of heavy cast iron parts by metal stitching and metal locking process.

Repair of Crack Casting is in Process
Repair of Crack Casting is in Process
Broken Engine Block Repaired After Metal Stitching, Metal Locking
Broken Engine Block Repaired After Metal Stitching, Metal Locking

 

 

 

 

 

 

 

We have executed more than 1000 jobs of crack repair all over the world successfully. We are considered to be most respected company in India and are cost effective.

Author of this blog is Raj Shahani, Managing Director of RA Power Solutions Pvt. Ltd. having experience of more than 37 years. He is instrumental in executing successfully repairs of crankshaft, metal stitching of broken engine block, crack repair of steel castings, metal locking of cylinder heads, etc.

For more information,

Please write: rajshahani@rapowersolutions.com

WhatsApp/Call:  +91-9810012383

RA Power Solutions undertakes crack repair and replaces castings broken into pieces due to accident by metal stitching and metal locking process. We have team of dedicated, trained and experienced technicians undertaking crack repairs of marine engines, compressors, plant machinery and heavy castings by metal stitching and metal locking process which is a proven method … Continue reading “Metal Stitching and Metal Locking Company in India”

Metal Surgery of Cast Iron

We were approached by leading shipping company operating in Middle East. One of their auxiliary engine model Daihatsu 6DK20 met with an accident and engine block window on which cover is fixed was broken in to pieces due to failure of connecting rod bolt.

RA Power Solutions Pvt. Ltd was appointed and we called for the photographs of the broken area of engine block with dimensions which is pasted below.

Broken Area of Engine Block with Dimesions
Broken Area of Engine Block with Dimensions
Broken Area of Engine Block of Daihatsu 6DK20
Broken Area of Engine Block of Daihatsu 6DK20

A rough drawing of engine block broken area which is of cast iron was prepared by RA Power Solutions Pvt. Ltd. technicians as below.

Rough Drawing Prepared by our techncician of Engine Block Broken Area
Rough Drawing Prepared by our technician of Engine Block Broken Area

Since the time was short, we manufactured a casting measuring 15 x15 inches and 2 technicians boarded the vessel. The job of repair of cast iron engine block was executed in a recorded minimum time. Engine is performing satisfactory.

We have all the latest tooling available for repair of cast iron, parts of diesel engine to the original shape and profile. The metal stitching and metal locking process followed by us to repair the cast iron gives more strength than the original casting.

 

We were approached by leading shipping company operating in Middle East. One of their auxiliary engine model Daihatsu 6DK20 met with an accident and engine block window on which cover is fixed was broken in to pieces due to failure of connecting rod bolt. RA Power Solutions Pvt. Ltd was appointed and we called for … Continue reading “Metal Surgery of Cast Iron”

Cracked Engine Block Repair

Crack in engine block develops due to various reasons including accident, constant high temperature of lube oil, extra ordinary stresses, etc. To replace crack or broken engine block works out to be time consuming and expensive.

Repair of Yanmar Diesel Engine Block
Repair of Yanmar Diesel Engine Block
Broken Engine Block of Yanmar Engine
Broken Engine Block of Yanmar Engine

 

 

 

 

 

 

 

RA Power Solutions Pvt. Ltd. undertakes crack repair of engine block by metal locking and metal stitching. The engine block casting which breaks in to pieces is also repaired successfully by metal stitching and metal locking process.

The new piece of casting is prepared and metal stitched in the broken area of the engine block.

New Piece Manufactured of Cast Iron for Metal Stitching
New Piece Manufactured of Cast Iron for Metal Stitching
Engine Block Repair Near Inspection Window
Engine Block Repair Near Inspection Window

 

 

 

 

 

 

 

We have the experience of more than 37 years of crack repair of cast iron, engine block, cylinder heads and heavy castings. We use high quality metal locks and metal keys which are imported from US and UK.

We have a team of trained technicians and ours is the only company which can undertake crack repair by metal locking and metal stitching process while the vessel is sailing.

Repair of Broken Engine Block by Imported Metal Keys and Locks
Repair of Broken Engine Block by Imported Metal Keys and Locks
After Repair of Engine Block, Grinding of Crankpin is in Process
After Repair of Engine Block, Grinding of Crankpin is in Process

Crack in engine block develops due to various reasons including accident, constant high temperature of lube oil, extra ordinary stresses, etc. To replace crack or broken engine block works out to be time consuming and expensive.               RA Power Solutions Pvt. Ltd. undertakes crack repair of engine block by metal … Continue reading “Cracked Engine Block Repair”

Crack Repair of Cast Iron

We have over 36 years of experience of undertaking cast iron crack repair by metal stitching and metal locking process which is proven and has various advantages over the crack repair by welding process.

We have successfully undertaken repair of crack and  broken cast iron and cast steel castings of engine block, cylinder heads, turbine casing, gearboxes and heavy plant and machinery by metal stitching and metal locking.

Repair of Engine Block
Repair of Engine Block
Broken Engine Block
Broken Engine Block

The consumables used by us to undertake crack repair and repair of broken casting are imported from USA and UK. All the repairs undertaken by us are executed by experienced engineers with guarantee. For ship owners we offer onsite metal stitching and metal locking services for crack repair while the vessel is on move. There is no need of anchorage of vessel or holding it at port.

Metal Locks and Keys Used in Metal Stitching Process
Metal Locks and Keys Used in Metal Stitching Process
Crankshaft Grinding After Metal Stitching
Crankshaft Grinding After Metal Stitching

 

 

 

 

 

 

 

We are the most cost effective for crack repair of marine engine  parts by metal stitching and metal locking can mobilize team of our technician with in a short notice of 6 hours.

Technicians have seaman passport and international travel can be organized in short time.

Crankpin After Grinding
Crankpin After Grinding
Crankshaft Grinding and Polishing
Crankshaft Grinding and Polishing

We have over 36 years of experience of undertaking cast iron crack repair by metal stitching and metal locking process which is proven and has various advantages over the crack repair by welding process. We have successfully undertaken repair of crack and  broken cast iron and cast steel castings of engine block, cylinder heads, turbine … Continue reading “Crack Repair of Cast Iron”

Advantage of Metal Stitching Process

RA Power Solutions Pvt. Ltd. undertakes repair of crack casting which is broken in to pieces by metal stitching and metal locking process. The company has executed successfully repair of more than 600 nos. of crack engine block, turbine casing, turbo charger casing, gearbox housings, etc. in last 3 decades.

It is proven that repair of crack in cast iron or cast steel, castings is successful by metal stitching and metal locking process in comparison to old welding process which was followed.

Advantages of crack repair by metal stitching and metal locking process are as follow:

I) Repair of cracks in engine block, cylinder heads, and turbines can be undertaken by metal stitching and metal locking process on site without disassembly of the equipment. This process of repair saves downtime and is cost effective.

II) Metal stitching and metal locking process provides an excellent expansion joint for engine parts like cylinder liners,crankcase, cylinder heads which are subject to thermal and mechanical stresses. The main advantage of repair of cracks by metal stitching and metal locking process is that no stresses are developed and the alignment is maintained with original surfaces as the lack of heat produces no distortion.

III) The procedure and process of repair of cracks by metal stitching and metal locking is accepted by various classes and inspection agencies.

IV) The process of metal locking and metal stitching is cold, no heat is generated and in most cases there is no need of replacement of heavy and expensive parts.

Metal Stitching and Metal Locking Process
Metal Stitching and Metal Locking Process

RA Power Solutions Pvt. Ltd. undertakes repair of crack casting which is broken in to pieces by metal stitching and metal locking process. The company has executed successfully repair of more than 600 nos. of crack engine block, turbine casing, turbo charger casing, gearbox housings, etc. in last 3 decades. It is proven that repair … Continue reading “Advantage of Metal Stitching Process”