METAL LOCKING

The metalock process consists of a series of steps, that uses metal alloy
'locks' or 'keys' that are inserted into the cast iron across and at right
angles to the fracture. The process is applied to a fracture, or to a complete
break in the material.

Metalock – Metal Stitching Process

Metal stitching is a unique emergency repair method of repairing cracks or
joining pieces of broken cast metal components without welding. Information
on the repair process and its advantages are covered in this article.

Cast iron is the most difficult of all common cast metals to weld. All electric
welding methods for cast iron have proven to be less than satisfactory and in
many cases have created even more cracks. In view of this, Metalock process
originated in the oil fields of Texas in the 1930s and is now recognised and used
throughout the world. Cold casting repairs carried out by Metalock are superior
to welding in the case of crack sensitive materials.

Repair Procedure
Various steps for carrying out repair are as under.
 The fracture is positioned, realigned and firmly held together by special
fixtures and clamps.
 Jigs are used to drill groups of holes across the line of fracture to the depth
of the casting and the holes are joined to form shape of Metalock Key.
 Individual layers of Keys are inserted in the apertures and peened into a
metal to metal condition, which becomes almost integral with the parent
metal of the component under repair.
 Holes are then drilled along the line of the fracture, tapped and filled with
studs. Each stud is fitted biting into its predecessor resulting in a pressure
tight joint. This is the main part of the process in which the crack is replaces
by the stitching studs.
 The surface is then peened and excess material is removed.
The repair is complete and component generally does not require further
machining.
 Drill bit Metalock Keys

A pump casing repaired by Metalocking is shown

below.

Advantages
The Metalock repair process is used successfully and recognised by the
Classification Societies. In many cases the equipment gives many more years of
productive service after repair. The advantages of the process are as under.

 Cold repair can be carried out to castings of cast iron, steel and non ferrous
alloys.
  Many repairs can be carried out onsite with minimal or no dismantling.
 Downtime of equipment is minimized as the broken pieces can be put
together to maintain alignment and original surfaces with little or no
machining requirement.
 A pressure tight seal can be achieved due to the interlocking between
Metalock keys and studding.
 Since the repair is done in a cold state, there is no distortion and
residual stresses are not introduced.
 The Key design is such that the load is gradually transferred from the Key
to the casting. This helps to dampen mechanical vibration and provides an
expansion joint when temperature fluctuations occur.

Engineering Classification Bodies

Comments from Lloyd's Register

"We have approved a number of Metalock International Association member companies for
the application of the process, but in addition each repair is assessed on a case by case basis.
The repairs have to be undertaken to a written procedure that is specific to the component
being repaired and been reviewed and accepted by Lloyd's Register prior to commencement
of the repair. The repair itself has to be undertaken with the Lloyd's Register surveyor in
attendance.
Repairs by metal stitching are recognized as temporary repairs. However, if the repair
has completed two years satisfactory service it may be recognized as a permanent
repair."
Comments from DNV

“We accept repair with stitching on engine blocks in low stress areas, and where there is no
risk of leaks (occasionally also when we consider that the risk of leaks can be adequately
controlled), for ships in operation. Experience is generally good."

Comments from Germanischer Lloyd SE

"Almost 100% of all repairs carried out by this method were successful.”

Oerlikon can provide a wide range of TIG AC/DC and DC power sources
(CITOTIG Force, CITOTIG II…). Our TIG rods offer covers non alloy steels, low &
medium alloy (CARBOROD Ni1...), high alloy steels (INERTROD 308L), and also
other materials.

Principle of the process

The TIG process uses the heat generated by an electric arc between the metals to
be joined and an infusible tungsten-based electrode, located in the welding torch.
The arc area is shrouded in an inert or reducing gas shield to protect the weld pool
and the tungsten electrode.
The filler metal as a rod is applied manually by the welder into the weld pool.
TIG welding is especially suited to sheet materials with thicknesses up to about 8
or 10 mm.
The metal transfer