Engine Block Repair Archives - Connecting Rod Repair

Metalock | Metal Stitching | Repair of Cracked Components

With over 45 years of global experience, R A Power Solutions specialises in the onsite repair of cracked and damaged components using advanced metal stitching and Metalock techniques. We regularly undertake metal stitching and metalocking for heavy industrial parts made from cast iron, cast steel, aluminium, bronze, and other critical engineering materials.

Components We Repair Using Metal Stitching & Metalock

We carry out onsite crack repair for a wide range of industrial components, including:

Bedplates
Forging hammers
Compressor bodies
Engine blocks and major engine components, such as cylinder liners and cylinder heads
Gearbox housings and similar heavy-duty castings

High-Quality Tools & Consumables for Reliable Repairs

Successful metal stitching requires precision, skill, and the right equipment. To ensure long-lasting repairs, we use:

Premium Pneumatic Tools
Imported pneumatic tools from leading U.S. manufacturers
Essential for preparing accurate profiles before stitching
Ideal for remote sites due to easy availability of compressed air

Specialized Metal Locks & Keys

Our repairs use high-grade metal locks, keys, and master locks. Selection is based on a metallurgical analysis of the damaged casting.
We always select consumables with superior properties compared to the parent material, ensuring a durable and high-strength repair.

Key Features of the Metalock Process

Cold process — no heat, no distortion, no stress on castings
Precisely placed locks mechanically reinforce cracked sections
Restores structural integrity without welding
Ideal for engines and heavy machinery where alignment is critical

Engine block window after repair — Metal Stitching

Advantages of Metal Stitching with Metal Keys

Keys are inserted across the crack to seal and tighten the casting
Overlapping patterns distribute load evenly
Repaired areas often become stronger than the original casting
Suitable for cast iron, aluminium, bronze, and cast steel
Cost-Effective Repair Solution

Metal stitching and metal locking provide a highly cost-efficient alternative to component replacement. Many industrial parts are:

Expensive to replace
Long lead-time items
No longer manufactured
Repairing them onsite saves money, reduces logistics, and keeps operations running smoothly.
Fast, Onsite, and Minimum Downtime

Metal stitching, a fast repair method, often enables completion within hours, directly at the site, without the need to dismantle the equipment. Metal stitching is a fast repair method that can typically be completed within hours, directly at the site, without dismantling the equipment. This drastically reduces downtime and allows machinery to return to service quickly.

Global Onsite Crack Repair Services

R A Power Solutions delivers onsite metal stitching, metalocking, engine block repair, and cast iron crack repair services in major industrial regions worldwide. Our teams are actively working on several international projects, providing reliable, high-precision solutions for critical equipment.

For inquiries or technical assistance:
📧 rajshahani@rapowersolutions.com

📧 info@rapowersolutions.com

📞 +91 9582647131, +91 9810012383.

With over 45 years of global experience, R A Power Solutions specialises in the onsite repair of cracked and damaged components using advanced metal stitching and Metalock techniques. We regularly undertake metal stitching and metalocking for heavy industrial parts made from cast iron, cast steel, aluminium, bronze, and other critical engineering materials. Components We Repair … Continue reading “Metalock | Metal Stitching | Repair of Cracked Components”

Lock and Stitch Cast Iron Repair | Metal Surgery | Cracked Engine Block Repair | Repair Cracked Cast Aluminum

RA Power Solutions undertakes the repair of crack or damaged engine components manufactured out of cast steel, repair cracked cast aluminum, cast iron, or aluminum. We follow the process of Metal Stitching & Metal Locking for repair of crack or damaged components. In most cases, the repairs are undertaken on-site without dismantling the major components. This results in the saving of downtime of the plant & money.

Metal Stitching | Metal Locking

RA Power Solutions is a leader in this field of repair of large damaged casting components by Metal stitching & Metal Locking, we offer crack repair services 24/7 through our technicians who are well experienced. Our senior-most technician executing crack repair by metal locking and metal stitching process has 44 years of experience and has a record of executing more than 1500 jobs which are saved from rejection and are performing satisfactorily.

The repair of Crack and damaged casting by Metal Locking & Metal Stitching process

RA Power Solutions was developed in late 1930 as a cold option for repair of Crack or damaged cast iron components & equipment. This process of casting crack repair has proved successful as it is cold and stress-free without the generation of any heat. Most of the crack repair jobs undertaken by us, it does not require machining. Our technicians have Indian CDC / Palau CDC which facilitates them to execute the Crack repair even while sailing the vessel this again proves to be of great advantage to the ship owners and the industries.

The author is Mr. Raj Shahani Managing Director of RA Power Solutions having experience of almost four decades of working on high-capacity diesel engines, turbines, and rotary equipment. The company specializes in executing the repairs i.e. metal stitching/metal locking, grinding and repair of crankshafts, rebabbitting of bearings, Cast Iron Repair, connecting rod reconditioning, overhauling of Engines which have serious problems resulting in the immense saving to the owners.

For more information about metal surgery, engine block repair, metal surgery process, cold metal repair, cast iron stitching, cast iron engine block repair, or broken engine block, engine connecting rods please email us at rajshahani@rapowersolutions.com or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

RA Power Solutions undertakes the repair of crack or damaged engine components manufactured out of cast steel, repair cracked cast aluminum, cast iron, or aluminum. We follow the process of Metal Stitching & Metal Locking for repair of crack or damaged components. In most cases, the repairs are undertaken on-site without dismantling the major components. … Continue reading “Lock and Stitch Cast Iron Repair | Metal Surgery | Cracked Engine Block Repair | Repair Cracked Cast Aluminum”

Thread Repair Insert | Crack Repair Engine Block Cover | Onsite Machining – RA Power Solutions

Wartsila 12V32 Engine Block Repair via Onsite Machining

RA Power repairs threads and cracks damaged in accidents. The advantages are:

Conducted Magnetic Particle Inspection (MPI) across the engine block using Level 3 certified technicians to detect cracks.
Performed dimensional measurement of main journal housings to assess taper and ovality.
We carry portable, lightweight machines to the site to repair damaged threads.
The team cut out the damaged block portion completely.
Fabricated a new casting section matching the original Wartsila 12V32 block profile.
Installed the new section using metal stitching and metal locking techniques.
Finalized with onsite machining to restore main journal housing bore dimensions within manufacturer specifications.

Engine Block Repair | Onsite Machining | Crack Repair

Serving the diesel power plants and shipping companies for the last four decades, we observed that in spite of the best maintenance protocols and process followed, accidents do take place. We have the history of repairing seriously damaged engine blocks.

Recently, a Wartsila engine suffered heavy damage on both sides of the block measuring 600 mm × 500 mm. The accident also damaged the main journal housings. A barge with six Wartsila 12V32 units housed the engine.

Why RA Power Solutions Is Your Go-To for Engine Casting Repairs?

Four decades of industry experience, serving diesel power plants and marine clients.
Highly skilled teams capable of delivering on-the-spot repairs, minimizing plant disruptions.
Our methods sidestep destructive heat-based procedures, offering cold, stress-free solutions.
We’ve helped salvage thousands of components through repair methods that avoid needless replacements

For more information on Crack Repair for Engine Block, Thread Repair, contact us at rajshahani@rapowersolutions.com or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

FAQs:

1. Can a cracked engine block be repaired?

Yes, it can be repaired using metal stitching and onsite machining.

2. Is welding safe for engine block crack repair?

No, welding often causes heat stress—metal stitching is safer.

3. How much does engine block crack repair cost?

It’s far more affordable than replacing the entire engine block.

4. Can engine block cracks be fixed without dismantling?

Yes, portable tools allow onsite repair without removal.

When accidents strike—despite the strictest maintenance—threads on engine blocks, turbine casings, and cam blocks often suffer damage, frequently accompanied by cracks around the threaded areas. RA Power Solutions has developed a robust, onsite repair process that restores functionality without dismantling the components. Wartsila 12V32 Engine Block Repair via Onsite Machining RA Power repairs threads and … Continue reading “Thread Repair Insert | Crack Repair Engine Block Cover | Onsite Machining – RA Power Solutions”