Metal stitching has been a recognized method since 1938 and has saved multiple machine frames, pumps, presses and engines from scrapping. The key characteristic of the metalock process is that it involves no heat strain in its application.
cast-iron-recovery-step-1 Step 1:

Using a drill jig, rows of blind holes are drilled perpendicular to the direction of the crack, each row to act as a key.  

 cast-iron-recovery-step-2 Step 2:

The intermediate partitions are removed with pneumatic chisel. 

 cast-iron-recovery-step-3 Step 3:

Metalock keys are driven into the openings and caulked.

 cast-iron-recovery-step-4 Step 4:

Holes for Metalock screws are drilled along the crack  between the keys.

 cast-iron-recovery-step-5 Step 5:

The screws are fitted so closely together that they overlap.

 cast-iron-recovery-step-6 Step 6:

Finally, the entire installation is caulked to ensure stability and pressure. 

 metalockning-3 metalockning-6
 metalockning-5 metalockning-2 

Metal-stitching process of damaged engine frame. This type of repair is a life lasting repair.

In-Situ Metalock Repair

Repairing broken, cracked or otherwise damaged cast parts always represents a great challenge as cast iron can only be welded to a limited extent. MAN PrimeServ On-site Recovery uses a special Metalock/Masterlock procedure as a viable alternative to welding that today is the preferred method in industry and marine shipping.

This procedure enables us to specialise in the cold repair of damaged industrial components made from cast iron, steel and aluminum. The Masterlock method is a cold-repair process that avoids the stress problems frequently associated with welding and, more importantly, maintains the original alignment, which lessens the requirement for re-machining following repair.

The Metalock International Association has developed and tested a new stainless key (MN555) to facilitate component repair at high temperatures of up to 550 degrees Celsius. The key is corrosion resistant and can also increase a repair’s return of strength.

The Metalock/Masterlock procedure offers many advantages and:

  • is a cold process that eliminates thermal stress and resultant component distortion
  • is an on-site repair that eliminates the need for disassembly and off-site transport
  • delivers a high pressure-tight seal that protects against oils and gases
  • minimises the downtime of valuable equipment
  • is recognised by classification societies
  • eliminates the need to purchase new, expensive cast-iron parts