Metalock Process

Casting Repair Process

The Metalock process, known as metal stitching, is a unique rapid and permanent method for repairing cracks or for joining pieces of broken cast metal components without welding.

Cold casting repairs carried out by Metalock International Association (MIA) members are superior to welding in the case of crack-sensitive metal. The repairs can take place in otherwise hazardous conditions for welding and cause minimal disruption to operations.

Each repair only requires equipment that can be carried by hand and is generally completed in a matter of days and can typically restore the strength of the equipment so that it will continue to operate to full specifications.

Using a drill jig, drill knockouts perpendicular to the direction of the crack. Each Row acts as a key.

Intermediate splits will be removed with a pneumatic chisel.

The openings made are sealed with METALOCK® keys.

Holes for METALOCK® screws are drilled along the cracks between the keys.

METALOCK® screws are placed, ensuring the seal throughout the fracture.

Finally, the installation is covered and sealed to guarantee stability, pressure adjustment and airtightness.

Advantages

Dampens and absorbs compression stresses. Provides a good ‘expansion joint’ for castings such as cylinder liners, cylinder head or any casings subject to thermal stress.
Distributes the tension load away from fatigue points.
Maintains relieved conditions of inherent internal stress where rupture occurred.
Maintains alignment and original surfaces, since lack of heat produces no distortion.
The vast majority of repairs can be done in situ, with consequent savings in time, with little or no dismantling.
A pressure tight seal can be achieved due to the interlocking between Metalock keys and studding.

Benefits

Can be performed in-situ, thus major dismantling is not required.
Produces permanent repairs that can be completed in days.
Does not require hot work, so can be performed in any area.
Can be used to repair cast iron and other metals.
Cost is almost always less than replacement Is accessible via a worldwide network of especially trained Metalock technicians, through the Metalock International Association.
Does not require heavy machinery or equipment to carry out repairs. Causes minimal disruption.
Reduces downtime.