Cast Iron Engine Block Repairs From Metalock Engineering

With over 70 years of experience in specialist engineering projects, you can rest assured knowing you are in safe hands with Metalock Engineering. Keep reading to learn more about our cast iron engine block repair service.

MAK 32 crankcase door repair

What Is a Cast Iron Engine Block?

So, what exactly is a cast iron engine block? The engine block provides a house for cylinders and other key parts of the engine, helping to protect against the forces produced during engine operation. Cast iron is used due to its strength, thermal conductivity, and wear resistance. While cast iron is an excellent material for engine blocks, it can also be brittle, which can lead to cracks that can put the entire engine at risk. This is why cast iron engine block repairs need to be carried out as quickly as possible to keep downtime to a minimum.

Industries That Use Cast Iron Engine Blocks

There are numerous industries that rely on cast iron engine blocks, which means that we have extensive experience helping businesses in wide-ranging sectors. A few of the most notable industries that use cast iron engine blocks include:

• Marine: Diesel engines are also used on ships and other marine vessels. Thermal cycling and exposure to corrosive elements can lead to cracks that need to be fixed as quickly as possible.
• Energy: The energy sector often uses diesel generators or steam turbines with cast iron engine blocks. Any issues with the cast iron engine block can disrupt power generation, which is obviously a major issue.
• Construction & Mining: Many machinery used in construction and mining uses cast iron engine blocks, including bulldozers and excavators. The harsh operating conditions in these industries can lead to cracks that can result in downtime.

Wartsila Vasa 32 damaged engine block

Damaged Cylinder liner housing

after cold Metalock repairs

Common Causes Of Cracks

Although cast iron is a strong and durable material, there are a few common reasons why cracks occur. These include:

• Corrosion: Exposure to corrosive elements in marine and industrial environments can weaken cast iron, eventually leading to cracks.
• Fatigue: Cracks can occur due to fatigue, which occurs due to repeated stress of engine operation. This occurs in parts of the engine block that have high-stress concentrations, including near the main bearings.
• Mechanical Overload: Excessive operational demands or sudden impacts can create stress fractures on the cast iron engine block.
• Thermal Stress: Heating and cooling cycles create thermal stress, which can lead to cracks in the engine block. This is a common issue when the engine block is used in environments with extreme temperatures and/or when the engine is started and stopped frequently.

Metalock Engineering’s Cast Iron Engine Block Repairs

Cast iron engine block cracks are a cause for concern as they can cost a fortune in downtime and repairs. Fortunately, Metalock Engineering has a patented Cold Metalock Process that is conferred to be the most effective method for repairing damaged, cracked, or broken components made from cast iron.

The Cold Metalock Process involves peening Metalock keys into prepared apertures. These keys are made from nickel alloys and peened into metal-to-metal condition, allowing them to become one with the cast iron engine block. The Cold Metalock Process is highly effective because it can help to restore the structural integrity of the unit.

Stork Werkspoor engine block damaged due to conrod failure returned to working condition

Additionally, the Cold Metalock Process is effective because it does not require the use of heat, which is how welding works. While welding can be effective for cast iron repairs, there are risks involved relating to thermal stress. Cast iron can be sensitive to thermal cycles, so welding can be a risk.

Another reason to use Metalock Engineering for your cast iron engine block repair needs is that we can carry out repair work onsite. Instead of having to remove the engine and send it away for repair (a major cost), we can send technicians to you to fix the engine block in situ. This can both speed up the repair process and help you make significant savings.

We are also on call 24/7, 354 days of the year. We have technicians available to travel and located around the world, which means that we can get to you as quickly as possible. This, combined with the ability to carry out repair work on site, means that cast iron engine block repairs can be carried out quickly and to a high standard while minimising disruption to your operation.

With decades of experience in cast iron repair work and supported businesses in wide-ranging industries, you can rest assured knowing you are in safe hands with Metalock Engineering. Our advanced Cold Metalock Process is a sophisticated technique that will prove to be more cost-effective than repotting the entire engine block.

Cast iron engine blocks are key components used in engines, which means that they are common in many different industries. Despite the strength of cast iron, cracks can appear for a few reasons. A cracked engine block can lead to downtime, which can be costly and impact your reputation. Therefore, cracks need to be fixed as quickly as possible to save money and get you fully operational again.