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Metal Stitching & Machining Repair of Cast Iron Diesel Generator

Step by Step Report Presentation (PDF - 4.72 MB)

El Salvador’s Nejapa Power identified damage in the cast iron engine block of their Wartsila diesel generator. The damage included holes into the coolant jacket, air box, lower liner bore, and cam box. At LOCK-N-STITCH Inc. we have the capability to repair large engines utilizing our metal stitching technology, onsite. The damaged section of the V18 cylinder engine was removed and new sections of cast gray iron patches were fabricated and installed utilizing Castmaster® stitching pins for the air box, lower bore, and cam side repair.

This offsite repair required the use of boring and milling machines, metal stitching tools, and liquid nitrogen which was used to press in the new bore sleeve.

Upon completion of the cast iron repair the Wartsila diesel generator was returned to factory specifications, and completed in just 4 weeks. This project exemplifies our ability to go anywhere in the world to provide cast iron repair.

To learn more about this project, see the table below or contact us directly.

Highlights of the Metal Stitching & Machining Repair Project

Cast Iron Crack Repair Capabilities Applied/Processes
Primary: Metal Stitching, Installation of new sections
Secondary: In-situ machining, boring, sleeving, milling
Equipment Used to Manufacture Part
Boring machine, boring and milling machines, metal stitching tools, liquid nitrogen
Overall Part Dimensions
Large V18 cylinder engine
Material Used
Castmaster® stitching pins, new sections of cast gray iron, liner bore sleeves,
Material Finish
Hand finished or machined to match all existing contours
In process testing/inspection performed
Magnetic Particle Inspection, Pressure Testing – Quality Assurance
Industry for Use
Power generation
Delivery/Turnaround Time
4 weeks, 2004
Delivery Location
El Salvador
Standards Met
Returned to factory specifications
Additional Facts
Wartsila Diesel Generator (customer is Nejapa Power)

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