Onsite metal stitching and metal locking provide a precise and permanent mechanical solution for repairing cracked or broken castings and machine components. This advanced technique eliminates the need for welding, ensuring structural integrity without introducing heat-induced stress or distortion. As a result, no post-repair machining is required to correct misalignment or warpage.
Since no heat is involved, metal stitching and locking can be safely performed in restricted areas where welding or open flames are prohibited. Repairs are executed directly at the site, reducing downtime and eliminating the need for major disassembly.
Ensuring uninterrupted production is a challenge, especially when critical equipment fails. Our crack repair by metal stitching process is designed to deliver a durable and reliable repair after a thorough analysis of the damage. With years of experience, we have perfected our craft, earning endorsements from equipment manufacturers, insurance providers, and inspection agencies for the quality and dependability of our work.
Restoring damaged components of engines and turbines without heat distortion.
Effective restoration of machine pillars, hammers, heavy tools, and forging presses.
In-situ repair of components in cement, fertilizer, steel, and sugar plants that suffer accidental damage.
Comprehensive crack repairs for cast-iron engine blocks.
A precise drilling fixture is aligned at right angles to the crack. A hole pattern is drilled at consistent intervals (3/4 to 1 1/4 inches apart).
The metal between drilled holes is carefully removed using pneumatic tools, creating a serrated slot.
Custom-engineered alloy locks are placed into the slots and peened in layers, ensuring strength and durability.
Additional holes are drilled and tapped along the crack’s length. Overlapping fasteners are applied to seal the fracture and reinforce the structure.
The repaired area is peened, flush-ground, and finished, restoring its original appearance.
For completely broken castings, new castings are manufactured to match the original metallurgy and profile. A pattern maker ensures precise replication, blending the new component seamlessly with the existing structure for both functionality and aesthetics.
Crack repair in engine blocks, entablatures, and fractured castings using metal stitching and locking.
Damaged thread restoration using metal stitching, locking, and helicoil inserts.
Our expertise in metal locking and metal stitching ensures durable repairs that restore equipment to optimal performance, reducing costs and downtime while maintaining structural integrity.
RA Power Solutions follows a proven onsite metal stitching and metal locking process to repair cracked cast iron components, damaged engine blocks, broken castings, compressor housings, turbine casings, and other critical machinery without welding. The repair is carried out at the customer's site, minimizing equipment downtime while restoring the original strength and integrity of the component.
A specially designed drilling fixture is accurately positioned perpendicular to the crack to maintain alignment and precision. A series of holes is drilled at uniform intervals, typically ranging from 3/4 inch to 1¼ inches, depending on the casting thickness, crack length, and operating load requirements.
The material between the drilled holes is carefully removed using precision pneumatic tools to create a serrated slot. This specially engineered slot provides a positive mechanical grip for the metal locks, ensuring maximum holding strength.
Custom-manufactured, high-strength alloy metal locks are inserted into the prepared slots. Each lock is peened into position in multiple stages, producing a permanent mechanical bond that restores the structural integrity of the casting without introducing thermal stresses.
Additional holes are drilled and precision-tapped along the entire length of the crack. High-strength threaded stitching pins are installed in an overlapping pattern, creating a pressure-tight seal while reinforcing the repaired section against vibration, cyclic loading, and future crack propagation.
After completion of the stitching and locking process, the repaired area is carefully peened, machined, and flush-ground to match the surrounding casting surface. The finished repair restores both the appearance and functionality of the original component while maintaining dimensional accuracy.
When a casting has fractured into multiple pieces or sections are missing, RA Power Solutions can successfully restore the component using advanced metal stitching and metal locking techniques.
Where replacement material is required, a new casting section is manufactured to match the original metallurgy, dimensions, and profile. Precision patterns are developed to ensure an exact fit with the existing casting. The replacement section is then mechanically integrated using metal stitching and metal locking, producing a repair that restores the original strength, alignment, and appearance of the component without the risks associated with welding.
Comprehensive Engine Block Repair Services
RA Power Solutions specializes in onsite repair of diesel engine blocks and heavy cast iron components used in marine, power generation, mining, steel, and industrial applications.
Our proven expertise in metal stitching, metal locking, engine block repair, cast iron crack repair, and broken casting repair enables us to restore expensive machinery to its original operating condition while avoiding replacement costs. Every repair is carried out without welding, eliminating heat distortion and residual stresses while ensuring long-term structural reliability and dependable performance.
