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Goltens’ Cast Iron Repair Minimizes Cost and Downtime

Cast Iron On-site Metal Stitching is often the only reasonable method to repair cast iron cracks and salvage what is

Repair / Metal otherwise a condemned component or major piece of machinery. Traditional welding methods are not
effective for repairing cast iron and other cast metals and in many cases can result in more damage to the
piece being welded.

Stitching

Metal stitching to repair cast metal damage has a The applications for the process are many and
variety of benefits: cover a broad range:

It provides a permanent crack repair without the introduction of Cracked Engine Block Repairs (sidewalls, liner bores)
heat associated with welding. Damaged Engine Bedplate repairs
It can be performed on-site avoiding the high costs associated Steam turbine repairs
with disassembly and transport. Repairing damage to heavy industrial machinery
The repaired area is restored to its original strength with a Metal crack repairs for mining equipment and large earth moving
watertight and gas tight repair. machinery
On-site machining and milling restores the surface of the repaired Damaged pump casings, gear boxes and gears
area to original dimensions

How to repair cast iron? This is how the metal stitching process works.

1. The image shows damage to a MaK
12M282 diesel engine block resulting from a
connecting rod failure. Without metal
stitching to repair the cast metal damage, the
block would be condemned.
2. After performing extensive crack tests to 3. A replacement cast iron insert section
ensure that all damage is captured, the matching the original casting is then shaped
damaged area is cropped out of the engine to the exact dimensions of the cropped
block leaving a clean surface to metal stitch a section of the block in preparation for
replacement piece into place. repairing the block.

4. This cast metal insert is then fit into the
hole in the damaged engine block, checking
for fit and grinding the insert as necessary to
unsure the mating surfaces have perfect
contact before beginning stitching.
5. Once the insert is fit, holes for the metal 6. Stitching pins are then screwed into place
stitching pins are drilled and tapped along the along the entire seam between the engine
mated seam between the block and the block and the cast metal insert. The stitching
insert. pins draw metal on both sides of the seam
together when they are tightened.

7. Once the seam is completely stitched, the
heads of the stitching pins are removed in
preparation for insertion of the locks.
8. Prior to lock insertion, the surface of the 9. Using a drilling template, a precision hole
stitched seam is machined using portable pattern matching the dimensions of the metal
machining tools and stress relieved and locks are made at various points along the
checked to ensure that there are no cracks or stitched seam.
irregularities.

10. Locks are then driven into the hole
patterns along the seam drawing the repaired
seam even closer together.
11. Once the locks are installed along the
seam, the surface is machined clean and the
repair is checked to ensure it is crack free
resulting in a watertight and gas tight repair
using a dye penetrant or other NDT method.

Case Studies

Case Study Case Study

Engine Block Repair – Metal Stitching Wartsila Is a repair even possible?

18V32LN

Case Study Case Study

Goltens Metal Stitching repairs salvage engine Metal Stitching Salvages Badly Damaged HP
block And LP Compressor Casings

All Metal Stitching Case Studies

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Engine Block Repair - Metal Stitching Wartsila 18V32LN