Repairing Crack Cast Iron by Metal Stitching Archives

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

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 lock after metal lock and metal stitching — Onsite Engine Block Repair

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

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”

Category: Repairing Crack Cast Iron by Metal Stitching

Metalock | Metal Stitching | Repair of Cracked Components

Components We Repair Using Metal Stitching & Metalock