Cast Iron Engine Block Repair Using Metal Stitching Techniques

RA Power Solutions was called by a client based in the Maldives to inspect the engine block of Wartsila 12V32 which got seriously damaged due to an accident.

RA Power Solutions technicians visited the island and undertook the inspection as per the following details:

  • Inspection of the engine block/entablature of the Wartsila engine, model 12V32.

  • On a visual inspection by our technicians, it was observed that the engine block developed multiple cracks near the inspection window.

  • A piece measuring 590 mm X 360 mm was damaged from the entablature casting and came out.

  • Our qualified technicians cleaned the surface area thoroughly, even the paint and the red oxide were removed.

  • The MPI was done for crack detection, and all the cracks were clearly identified.

  • The measurement of broken casting was also taken.

The details of the crack observed are as follows: -

  • Multiple cracks having a length ranging from 20 mm to 430 mm were observed.

  • The discipline profile of the damaged portion of the Wartsila engine block was given by cutting and grinding the final dimensions, which were observed as 660 mm X 396 mm.

Non-availability of Wartsila 12V32 engine block
Diesel engines are widely employed in the power, maritime, and heavy engineering industries around the world. Engine failures can occur as a result of poor handling, material faults, or insufficient maintenance, frequently leading to significant breakdowns with serious repercussions.

Such occurrences can result in substantial damage to important engine components, as well as the danger of injury to engine room personnel.

Traditional repair procedures, such as welding, can exacerbate the condition. The strong, localized heat generated during welding causes the casting to expand and contract, resulting in internal strains in the engine block or entablature.

Before the arrival of RA Power Solutions personnel, the diesel power plant owners had examined a variety of repair methods, including welding. However, our technicians described the difficulties associated with welding cast iron components. Because of its high carbon concentration, cast iron is prone to carbon burn-off during welding, making the repair procedure more difficult and unreliable.

In some cases, the welding, due to the high-temperature process, also results in the hardening or, rather, development of more cracks. We have also experienced that due to stress and contraction, there is a significant loss of the centerline of the main journal housings of the block, which is of great importance.

Repair of Wartsila 12V32 engine block by metal stitching and metal locking process

The engine block and entablature of the Wärtsilä 12V32 engine were successfully repaired with metal stitching and metal locking. This is a well-known cold repair process for recovering damaged cast iron, aluminum, and steel cast components, such as broken engine repair.

The procedure involves using specifically designed screws and locks to mend cracks and restore damaged sections. All discovered cracks were fixed using metal stitching. The severely damaged area of the engine block was repaired by installing a new casting piece that was securely incorporated, utilizing the metal stitching method.

After the repair, the engine was tested under load and found to work satisfactorily. This repair was completed in 2013, and the engine has operated reliably ever since then. The client avoided the expensive expense of replacing the engine block while minimizing downtime, which is crucial for power production operations in the Maldives.

RA Power Solutions employs a dedicated team of highly skilled specialists, led by an engineer with over 44 years of experience fixing cracks in cast iron, aluminum, cast steel, and steel components utilizing metal stitching and metal locking procedures.

All technicians have relevant CDC certifications and are available for immediate deployment internationally. They travel with small, lightweight pneumatic tools as checked baggage, allowing for on-site repairs.

RA Power Solutions has successfully completed repair projects in several countries, including Madagascar, Oman, Qatar, the Philippines, Bahrain, Sri Lanka, Bangladesh, Myanmar, Turkey, Nigeria, Greece, Saudi Arabia, the United Kingdom, Dubai, United Arab Emirates, Kuwait, Malta, Cyprus, Singapore, Malaysia, Colombia, Indonesia, Hong Kong, Spain, the Netherlands, Portugal, Estonia, Morocco, Belgium, Vietnam, and Canada.

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

Source URL: https://metalstitchinglocking.com/broken-engine-block-repair-cast-iron-fix-by-metal-stitching/

Watch Our YouTube Video: https://www.youtube.com/channel/UCxcP2Jc6DGFdpBokIcxVyBg 
Location: 411, 4th Floor, Arcadia, South City II, Sector 49, Gurugram, Haryana 122018, India

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