Metal Surgery of Cast Iron | Cast Iron Crack Repair
Industries widely use cast iron in heavy industrial and marine applications because of its excellent strength and heat resistance. However, even the toughest cast iron components may develop cracks or break due to accidents, overload, stress, lubrication failure, or fatigue. If not addressed correctly, such damage can lead to catastrophic failure of machinery, costly downtime, and expensive replacements.
At RA Power Solutions, we specialise in cast iron metal surgery and crack repair. We use advanced techniques that restore structural integrity and performance without the drawbacks of traditional welding methods.
A leading shipping company operating in the Middle East approached us for assistance. One of their auxiliary engines, a Daihatsu 6DK20, met with an accident. A connecting rod bolt failure breaks the engine block window, where the cover is fixed, into multiple pieces.
RA Power Solutions Pvt. Ltd. technicians prepared a rough drawing of the broken cast-iron area of the engine block, as shown below.
Cast Iron Metal Surgery
Metal surgery refers to a group of cold repair techniques designed to restore cracked or broken cast iron parts without excessive heat. Unlike welding, which generates heat and can distort the component, metal surgery methods preserve the material’s original alignment and dimensions. These processes include metal stitching, metal locking, cold stitching, brazing, fusion techniques, and controlled stress relief treatments.
Since the time was short, we manufactured a casting measuring 15 x 15 inches, and two technicians boarded the vessel. The job of repairing the cast-iron engine block was executed in a recorded minimum time. The engine is performing satisfactorily.
We have all the latest tooling available for the repair of cast iron. The parts of the diesel engine are to return to their 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.
Cast iron crack repair requires a skilled approach, tailored to the type and severity of the cracks present. By employing metal surgery techniques like cold stitching, metal stitching, fusion welding, brazing, and stress relief heat treatment, it is possible to restore the functionality and structural integrity of cast iron components.
If you encounter cracked cast iron machinery or parts, consult us. We are professional metallurgical experts who specialise in cast iron repairs. crack repair services, ensuring the best possible outcome.To know more about metal stitching, cast iron crack repair, please email us at rajshahani@rapowersolutions.com & info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.
Frequently Asked Questions (FAQs)
A: Cast iron metal surgery repair is a set of techniques like metal stitching, metal locking, and cold crack repairs used to restore cracked or damaged cast iron parts without welding heat.
A: Metal surgery uses cold processes that do not produce heat, preventing distortion, internal stresses, and weakening issues commonly seen in traditional welding.
A:Yes, technicians can perform most cast iron metal surgery repairs onsite without dismantling the equipment, saving time and reducing logistic costs.
A:We can effectively repair engine blocks, cylinder heads, pump casings, gearbox housings, turbine parts, and many other cast iron or metal components.
A: Yes, it avoids the high cost of replacement and minimises downtime, making it a highly cost‑effective solution.
