Onsite Crack Repair By Metal Stitching And Metal Locking

Crack Repair by Metal Stitching | Metal Locking | Metal Surgery

Reliable Onsite Repairs for Broken Castings and Machine Parts

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.

Metal Locking Under Process

Minimizing Downtime, Maximizing Efficiency

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.

Key Applications of Onsite Metal Stitching and Metal Locking

Crankcase & Turbine Casing Repairs –

Restoring damaged components of engines and turbines without heat distortion.

Repair of Cracked or Broken Castings –

Effective restoration of machine pillars, hammers, heavy tools, and forging presses.

Industrial Machinery Repairs –

In-situ repair of components in cement, fertilizer, steel, and sugar plants that suffer accidental damage.

Engine Block Repairs –

Comprehensive crack and fracture repairs for cast iron engine blocks.

Onsite Metal Stitching and Metal Locking Process

Drilling and Pattern Formation –

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).

Slot Formation –

The metal between drilled holes is carefully removed using pneumatic tools, creating a serrated slot.

Insertion of High-Tensile Locks –

Custom-engineered alloy locks are placed into the slots and peened in layers, ensuring strength and durability.

Threaded Fasteners for Reinforcement –

Additional holes are drilled and tapped along the crack’s length. Overlapping fasteners are applied to seal the fracture and reinforce the structure.

Finishing & Surface Restoration –

The repaired area is peened, flush-ground, and finished restoring its original appearance.

Handling Broken Castings:

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.

Comprehensive Engine Block Repair Services

Crack repair in engine blocks, entablatures, and fractured castings using metal stitching and locking.

Main journal housing inspection and correction.

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.