Metal Stitching and Metal Locking

Product Details:

Crack Repair by Metal Locking is done by trained technicians. Keys and master locks are used for repairs.

Product Details:

Our sytem holds expertise in provide high quality of Broken Casting Repair By Metal Locking.

Product Details:

The Metal Stitching process undertaken by us is a precise mechanical method of making permanent repairs of broken casting and machine parts. We ensure that no post-repair machining is required to correct misalignment and warp age as we don't use heat, which leads to stresses. Further as there is no heat, metal locking repairs can be provided in restricted areas where flames or welding arc is prohibited. Thus, the repair work can be carried out at location in the plant, without the necessity of major dis-assembly.

 

Features:

• Maintaining production and reducing down time of broken equipment presents many new challenges
• We provide solutions after a careful analysis and then applying our experience to make a proper, dependable repair
• The quality and craftsmanship thus achieved have earned for us the recommendation and endorsement of equipment manufacturers, insurance underwriters and inspection services

 

Procedure:

• Drilling fixture is attached of right angles to the crack
• A hole pattern is drilled and this is repeated at intervals from ¾ to 1 ¼ inches apart.
• Metal between each drilled hole is removed by ripping it away with pneumatic tools to form a slot
• The stock thus removed is narrower than the drilled hole, thus forming a serrated opening
• Preformed locks of high tensile alloy are inserted in to the slot. These locks are peened into the slots, one on top of the other, to a depth limited by the casting thickness and determined by the strength required.
• After the locks are installed, holes are drilled, 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
• Entire repair area is peened flush and finish ground
• In case of the broken casting, the new casting is manufactured in accordance to the metallurgy of the parent casting. The assistance of pattern maker is taken to manufacture the casting strictly as per the profile of the damaged area
• The necessary care is taken even for aesthetic look of the new casting which fully gets merged with the old one.

We extend metal stitching services all over the world including countries like Madagascar, Oman, Qatar, Philippines, Bahrain, Srilanka, Bangladesh, Myanmar, Turkey, Nigeria, Greece, Saudi Arabia, UK, Dubai, Malta, Cyprus

 

 

Product Details:

Onsite metal stitching of cast components manufactured out of grey cast iron, aluminium, bronze is undertaken. We have successfully executed repair of engine blocks of high capacity Wartsila engine like 12V32, 18V32, 12V46 etc. The successful repair by metal stitching, metal locking, metal surgery of casting is executed by our trained technicians who have experience of more than 30-40 years. Save your components from rejection. Contact us before replacement and for inspection.

Product Details:

Tapered cast iron threads are repaired onsite. It is generally observed that tapered threads in components get damage due to heavy stresses wear and tear, accident etc. We have the necessary tools, process and experience to undertake repair of threads which are damaged. We follow the process of metal stitching, metal locking and metal surgery for repair of damage or crack threads developed in cast iron, aluminium or bronze components.

Product Details:

Crack in engine block, cylinder head, turbocharger casing and all cast iron spares are repaired by metal surgery process. This process of crack repair is cold as it doesnt generate any heat and is successful.  Engine block repair is possible while sailing of the vessel.

Product Details:

We are associated in repairing cracks without welding. We have very high success rate to repair of cracked engine block. Most of the times our experienced engineers repair the cracked engine block without disassembly of the engine. The success rate of repair of crack by metal stitching and metal locking process is very high in comparison to welding process which is outdated develops heat resulting to development of multiple cracks

Product Details:

The repair of components manufactured out of cast iron by metal locking, metal stitching and metal surgery has become quite common. The heavy engine components like engine block, cylinder heads, turbocharger casing and heavy components installed in industries are regularly repaired by metal lock, metal stitching and metal surgery. The repair of aluminium component which gets damaged requires experience and necessary skill to execute the repair . RA Power Solutions have been regularly undertaking repair of aluminium pistons which develop crack. The crack in aluminium piston are clearly identified by undertaking MPI. We have the technology and equipment to execute the crack repair in aluminium piston or any component manufactured out of aluminium.

 The lock and keys used for crack repair of aluminium piston and aluminium components is of very advanced metallurgy which is not commonly available commercially. RA Power Solutions have saved hundreds of old engines by repairing damaged pistons which were no more manufactured. Irrespective of length and diameter of aluminium piston we undertake the repairs of aluminium piston with guarantee on site.

Product Details:

We undertake crack repair in grey cast iron, aluminium and cast steel  components by cold process named as metal stitching, metal locking and metal surgery. As a diesel engine repair and overhaul company with four decades of experience, we understand the criticality and load factor of the major components of engines. For the crack repair of components, planning is done based on its application, stress and load characteristics. The use of special metal lock, keys is decided by our experienced engineers based on the extent of cracks. All the repairs undertaken by us by metal stitching and metal locking of grey cast iron, aluminium and cast steel components is guaranteed for satisfactory performance.

We extend metal stitching services all over the world including countries like Madagascar, Oman, Qatar, Philippines, Bahrain, Srilanka, Bangladesh, Myanmar, Turkey, Nigeria, Greece, Saudi Arabia, UK, Dubai, Malta, Cyprus.

Product Details:

Due to an accident, upper portion of engine block/engine entablature was broken. On inspection of engine block, it was found that a upper engine block cast iron piece measuring 108 inches x 72 inches was broken in to pieces.

New cast iron piece was cast, metal stitched and metal locked and engine block/engine entablature is successfully repaired. Engine is performing satisfactory.

Product Details:

The photograph shows repair of pump housing which got damaged due to an accident. The housing cover was broken into pieces. RA Power Solutions have undertaken the repair of crack and damage pump housing by cold process of metal lock and metal stitching. The pump housing after repairs is performing satisfactory.

Product Details:

RA Power Solutions has successfully undertaken repair of damage engine block. As shown in the photograph, the engine block measuring 14 inches by 19 inches was badly damaged into pieces. A new piece was cast and was metal stitched and metal locked. The outer surface was properly grinded and painted. 

The engine block after repair by metal lock, metal stitching process is performing satisfactory. Considerable amount has been saved by avoiding the purchase of new engine block.

Product Details:

Engine block of CKD 1450 KVA skoda DG set met with a serious accident. Portion measuring 26 inches by 13 inches was damaged. With multiple cracks at different locations of the engine block, cracks were also observed on the liner sitting area of the CKD 1450 KVA skoda DG set. The cracks were properly identified by undertaking magnetic particle test. The cracks were repaired by using keys and master locks. The damaged portion of engine block was given a discipline profile and new piece of casting was manufactured. The preparation of pattern, manufacturing of casting was done under the supervision of RA Power Solutions engineers. The new piece of casting was assembled on the parent body of the crankcase and was metal stitched, metal locked. RA Power Solutions has forty years of experience in undertaking repair of crack and repair of damage casting.

Product Details:

The photograph shows repair of crack cast iron body of 200 MT forging press which was repaired by RA Power Solutions by metal stitching and metal locking. Considering the load characteristics of forging press, the master locks of different shape and profile were used. This job was executed in year 2013 and is performing satisfactory.

Product Details:

Due to overheating, Wartsila cylinder heads developed multiple cracks. The picture illustrates the crack location on the valve sitting area of the cylinder head. This was successfully repaired by metal stitching, metal locking and metal surgery process.

RA Power Solutions regularly undertakes crack repair of cylinder heads, cylinder liners, aluminium pistons engine blocks, turbocharger casing etc by metal lock and metal stitching for all makes and models of engine like Wartsila 6R32, 12V32, 18v32. Mirrlees Black Stone ESL, MAJOR K series Generators, Ruston, Allen, Yanmar, MAN B& W, Daihatsu, Caterpillar engine etc.

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RA Power Solutions was informed regarding the damage of roller guide casing of one of the auxiliary engine of a vessel sailing near Singapore. Our technicians boarded the vessel and after inspecting the damage, repaired the roller casing and cover. The threads were also redone. The photograph illustrates clearly the damage of guide pin, guide holes and threads. Photograph also illustrates the casing after the repair was successfully executed. The damaged threads were repaired by the combination of metal stitching and by use of thread plugs.

With the experience of over forty years in the field of in site repair of heavy equipments, we have executed the process and technique of crack repair in cast iron, aluminium casting and bronze heavy equipments by Metal lock and Metal stitching. We use pneumatic   light-weight tools and expertise of our technicians to successfully undertake crack repair in all types of heavy equipments manufactured out of casting. The repair of broken casting by metal stitching and metal locking process is a cold method of repair which is now acclaimed all over the world including sectors like aviation, defence and the industries manufacturing critical equipments. We undertake crack repair of steel, aluminium, bronze, cast iron, cast steel components.

We have experience of undertaking crack repair where the repairs by welding process fail and rather further damage the casting. This is done by removing the piece of damage/ weak casting and replacing it by new cast piece having the superior or same metallurgical properties. All the repairs undertaken by us are guaranteed for satisfactory performance.

 We have a team of highly experienced technicians for the shipping industry. Our technicians have valid seaman book and fly out to any destination in the world in a short notice. 

Recommendation for repair of crack by metal stitching and metal locking for following equipments:-

·         All the cracks irrespective of the length and width in cast iron, cast steel, aluminium and bronze can be repaired successfully by metal stitching, metal locking and metal surgery process.

·         Damaged blocks, cylinder heads, cylinder liners, aluminium pistons, turbocharger casings. 

·         All fractures developed in large and heavy equipments due to excessive stress, ageing or accidents can be repaired by metal lock and metal stitching.

·         Threaded holes and normal drilled holes damaged due to accident can be metal stitched.

·         Repair of broken lugs and studs

·         Repair of wind mill, heavy pillars, casings by metal lock and metal stitching.

Our technicians visit your site.

The main advantage of repair of damage casting or crack is that our technicians are available 24 x 7 and can reach your site in no time to execute the repair by metal stitching and metal lock process.

The light-weight pneumatic tools are carried by our engineers to the site along with consumables to attend the damage. In most of the cases, there is no requirement of dis assembly of the equipment hence the repairs are executed in short time duration and damage equipment can be put back into operation in minimum time with guarantee.

With more than 40 years of experience in the field of repairs, we understand the importance of successful repair and our technicians are trained accordingly.The training to our technicians on job is given in our in house school based near New Delhi this gives us confidence and we extend guarantee for the period of 12 months from the date of execution of repair for satisfactory performance. 

Product Details:

our system hold expertise in providing the Metal Locking of Cylinder Heads.

Damage of cast iron, aluminium and bronze equipment cause heavy losses to the owners. The repair of crack in cast iron heavy equipments is not successful by welding process and in most of the cases results to rejection of the equipment and heavy losses. With the introduction of crack repair technology i.e. metal stitching and metal locking, it is now possible to undertake damage cast iron repair by metal stitching and metal locking process.

 

 A cold process no heat is generated and in most of the cases no machining is required. The repair of crack in damaged cast iron engine block, compressor casing, turbocharger casing, cylinder liners is successfully undertaken with guarantee.

Product Details:

Casting Repair is done by Casting Repair By Metal Locking and Metal Stitching process.

Product Details:

Repairing cast iron components has become easy now by introduction of metal stitching and metal locking process. There is no requirement of repairing crack in the cast iron component by welding process which generates excessive heat and in some cases loses the original profile. RA Power Solutions Pvt. Ltd. undertakes repair of crack or damage cast iron component by a cold process metal lock, metal stitching and metal surgery. The execution of crack repair by experienced technicians, use of special alloy lock and keys and the process followed for repair is of great importance in successful repair of damage and crack components. With the experience of more than 41 years in the field of cast iron crack repair, we can claim successful repair of damage casting or cracked castings in 99% of cases.

 All the jobs executed by us of crack repair by metal lock, metal stitching and metal surgery are guaranteed for satisfactory performance.

RA Power Solutions is capable to execute the repair even while the sailing of the vessel.

We extend metal stitching services all over the world including countries like Singapore, Malaysia, Colombia, Indonesia, Hong Kong, Spain, Netherlands, Dubai, Portugal, Estonia, Morocco, Belgium, Vietnam, Canada.