cold metal stitching engine block Archives

Cast Iron Crack Repair | Metal Stitching Crack Repair | Repairing Crack Cast Iron by Metal Stitching & Metal Lock – RA Power Solutions

Metal stitching and metal lock process of repairing a crack casting or complete damage of cast iron parts of large equipments is considered to be the ultimate solution of successful repair. The repair of cracks and repair of damaged casting by metal locking or metal stitching process is simple and most effective method of repairing cracks in cast iron and aluminium components. The process is entirely a cold process and no heat is generated like in process of crack repair or damage casting repair by conventional and old method of welding.

RA Power Solutions having experience of more than forty years in providing cold metal stitching cast iron, onsite repair, and metal locking services for high-capacity main engine, auxiliary engine, and large and heavy rotary equipment installed on vessel or in industry. We extend crack repair services through our experienced and factory-trained technicians.

The following are the main features of crack repair undertaken by RA Power Solutions:

Detection of crack in cast iron or aluminium components: It is important that proper procedure is followed by experienced technicians to detect the exact location, length, and intensity of the crack. We have experience that in most of cases, no procedure is followed to identify the intensity of the crack which results to the failure of the component even after the repair by metal lock and metal stitching.

RA Power Solutions possess latest equipment to undertake MPI (Magnetic Particle Inspection) by qualified level 2 technicians, and we give great importance to the detection process of the cracks. The unattended cracks can grow and result to the failure of the component.
Once the number of cracks, length of crack, intensity, and depth of crack is determined and identified the repairs are undertaken by the metal stitching and metal lock process.

Some of the advantages of repairing cracks by metal stitching metal lock are mentioned below:

It is our experience that the majority of repairs of damaged components or cracks can be repaired on site with no requirement of dismantling the equipment. This reduces the downtime and of course the cost involved in dismantling and transportation of the equipment.
Repair of cracks and repair of damaged gray iron casting or aluminium by metal stitching and metal lock process does not generate any heat. Thus, it does not require any machining process. No alignment or profile is damaged.

In the case of diesel engines, compressors, or rotatory equipment majority of the parts are of aluminum or cast iron. It is possible to repair them by metal stitching metal lock process. Hence, no need of replacement of parts. It reduces cost of maintenance considerably.
Repair of crack by metal stitching metal lock process absorbs compression stresses which is of great advantage.

RA Power Solutions have been extending metal stitching, metal lock, and metal surgery services all over the world. The technicians with years of experience come to your site or on board the vessel for repairs. Our technicians possess Indian CDC and can board the vessel and sail in shortest possible time. Thousands of jobs of serious damage have been repaired successfully by RA Power Solutions.

For more information about cold metal stitching, metal stitching crack repair, cast iron metal stitching, repair of crack in cast iron casting, repairing cast iron metal lock, and metal locking services, please email us at rajshahani@rapowersolutions.com or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

Metal stitching and metal lock process of repairing a crack casting or complete damage of cast iron parts of large equipments is considered to be the ultimate solution of successful repair. The repair of cracks and repair of damaged casting by metal locking or metal stitching process is simple and most effective method of repairing … Continue reading “Cast Iron Crack Repair | Metal Stitching Crack Repair | Repairing Crack Cast Iron by Metal Stitching & Metal Lock – RA Power Solutions”

Metal Stitching | Metal Locking | Repair of Cast Iron by Metal Stitching – RA Power Solutions

When cast-iron or aluminum engine blocks crack, the traditional fix—welding—is often expensive, risky, and destructive. At RA Power Solutions, we specialize in advanced cold repair techniques—metal stitching and metal locking—that restore structural strength without applying heat, requiring machining, or dismantling equipment.

With the improvement in repair technology now, it is possible to repair the crack in cast iron, steel, or aluminium component by metal stitching and metal locking process. The main feature of repair of crack or damaged casting by metal stitching, metal locking, and metal surgery is that process does not require disassembly of the equipment and taking the crack or damaged part to the workshop.

What Are Metal Stitching & Locking?

Metal Stitching is a precise, cold repair method. Technicians drill a series of aligned holes across the crack, insert metal “keys” or studs into a dovetailed pattern, and tighten them so they interlock—effectively sealing the fracture and restoring rigidity.
Metal Locking reinforces the stitching with custom-shaped metal inserts that prevent the crack from spreading further and enhance the repair’s long-term durability

New Casting Inserted for Repair of Engine Block

RA Power Solutions has the team of experience technicians. They can travel to the site with tools and consumables required for metal stitching and metal locking undertake the repair.We repair cracks by metal locking and metal stitching while maintaining the original profile. In most cases, the process does not require any machining. Scientific tests prove that the repaired crack portion has greater tensile strength than before.

RA Power Solutions with the experience of forty five years in this field extends metal locking and metal stitching services for repair of damaged casting. We can also execute the repair while the vessel is sailing. We offer the lowest cost compared to our competitors.

Metal Stitching | Repair Cast Iron | Cast Iron Repair

Get your crack or broken components manufactured out of cast iron, cast steel or aluminium repair by metal stitching and metal locking process. RA Power Solutions with experience of more than four decades have successfully repaired thousands of major engine components and components installed in heavy industries all over the world.

The damage to the component may be serious, or the cracks are multiple. RA Power Solutions engineers have the experience, know how and necessary tooling to execute the most complicated and serious damage which takes place due to accidents in cast iron, cast steel and aluminium casting.

For more information on cold metal stitching engine block, cast iron engine block repair, metal stitching surgery, metal stitching engine block, repair cast iron, and metal stitching of engine block please email us at rajshahani@rapowersolutions.com or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

Metal Stitching & Metal Locking of Engine Block Under Process

Metal Stitching of Engine Block by Special Keys & Locks

FAQs:

1. What are metal stitching and metal locking?

Metal stitching involves drilling a series of aligned holes across a crack, inserting interlocking metal keys or studs, and tightening them to seal the fracture. Metal locking uses custom-shaped inserts that reinforce and prevent crack propagation.

2. Do these methods require dismantling the equipment?

No. We perform the repairs in situ, without disassembling the machinery or removing the damaged part from its position

3. Will the original surface or shape be affected by the repair?

We maintain the original profile after metal stitching and locking, and in most cases, no machining is needed afterward

4. Is the repaired area as strong as the original component?

Yes. Scientific studies show that crack areas repaired by metal stitching and locking often have greater tensile strength than before

5. Can repairs be performed while the vessel is underway?

Absolutely. We can execute repairs while the vessel is sailing, minimizing downtime and logistical challenges

When cast-iron or aluminum engine blocks crack, the traditional fix—welding—is often expensive, risky, and destructive. At RA Power Solutions, we specialize in advanced cold repair techniques—metal stitching and metal locking—that restore structural strength without applying heat, requiring machining, or dismantling equipment. With the improvement in repair technology now, it is possible to repair the crack … Continue reading “Metal Stitching | Metal Locking | Repair of Cast Iron by Metal Stitching – RA Power Solutions”

Metal Stitching and Thread Repair Inserts – RA Power Solutions

One of our clients informed RA Power Solutions about damage to the cam case cover of a MAN diesel engine on board a vessel sailing near China. After reviewing the details and photographs, we observed that the cam case cover had broken into pieces. We also found that the threads on the engine body and the dowel pin were damaged.

RA Power Solutions Executes Onboard Repair of Engine Block and Cam Case Cover Sitting Area:

RA Power Solutions deputed their team of technicians on board the vessel, and they executed the repair of engine block, cam case cover sitting area by the following procedure:

The broken bolt which remained inside the thread hole was drilled out.
The damaged threads on cam cover sitting area on entablature was removed by drilling new blind holes, suiting the new M12 Helicoil thread inserts.
Re-tap holes for the new M12 Helicoil thread inserts was done carefully.
New M12 Helicoil thread inserts were installed in the engine frame/ entablature.
The 2 guide pins for the roller guide housing were removed, taking due precaution.
Technicians installed a new roller guide housing using correct M12 hexagon bolts. They also included the newly introduced 10 mm washers.
Technicians completed the final alignment of the roller guide housing. They then tightened the bolts using the correct tightening torque.
Technicians drilled two ø8 mm guide pinholes in both the roller guide housing and the engine frame. Afterwards, they installed new guide pins.

**repair of Threads on Engine Block Under Process**

**Repair of Thread Hole by Metal Stitching**

What Is Metal Stitching?

Metal stitching, also known as metal locking, uses a cold repair technique to fix cracked or broken cast components. This method eliminates the need for welding. The process restores original strength and ensures pressure-tight sealing through mechanical locking of stitching pins and studs.

Advantages of Metal Stitching Over Welding:

No heat means no distortion, warping, or residual stress
Maintains alignment and surface profile of the original cast
Suitable for cast iron, steel, aluminum, and other alloys
Creates permanent, pressure- and liquid-tight repairs
Enables on-site repairs with minimal disassembly
Often stronger than the original material

Damaged Thread Hole Under Metal Stitching and Metal Locking

Metal Stitching of Bottom Area of Threaded Hole to Give Extra Strength

Our Process at RA Power Solutions:

Damage Inspection & Assessment: Document cracks and thread damage
Thread Repair via Stitching & Inserts: Use stitching keys and Helicoil/insert methods
Post-Repair Finishing: Grind and align to restore original surface
Testing & Validation: Conduct pressure or stress tests to ensure integrity.

With decades of experience and advanced cold-repair tools, RA Power Solutions delivers efficient and durable repairs without removing heavy castings.

Cam Cover Sitting Area of Engine Block After Repair

For more on metal stitching and metal locking, metal stitching of engine block contact us today email us at rajshahani@rapowersolutions.com, info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

FAQs:

1. What is metal stitching, and how does it work?

Metal stitching, also known as cold metal locking, is a mechanical repair process used to fix cracks in cast iron or cast steel components. It involves inserting stitching pins and locks to restore structural integrity—without welding or heat.

2. When should I use thread repair inserts like Helicoil?

You should use thread repair inserts when original threads in an engine block, casing, or housing become stripped, worn out, or damaged. Helicoils restore the thread’s strength and allow secure fastening, even under high torque.

3. Is metal stitching better than welding for cast iron repair?

Yes. For cast iron and other brittle materials, metal stitching is safer and more reliable than welding. It avoids heat distortion, cracking, and structural weakening, which are common risks with welded repairs.

4. Can RA Power Solutions perform these repairs on-site?

Absolutely. RA Power Solutions specializes in on-site metal stitching and thread repair, including work on marine vessels, power plants, offshore rigs, and remote industrial sites—without the need to remove the equipment.

5. What components can be repaired using metal stitching and thread inserts?

These techniques can repair engine blocks, cylinder heads, gearboxes, cam case covers, pump casings, compressors, and more. These methods can typically restore any cracked or damaged cast iron or steel component.

One of our clients informed RA Power Solutions about damage to the cam case cover of a MAN diesel engine on board a vessel sailing near China. After reviewing the details and photographs, we observed that the cam case cover had broken into pieces. We also found that the threads on the engine body and … Continue reading “Metal Stitching and Thread Repair Inserts – RA Power Solutions”