Cylinder Head and

Turbo Charger Casing

Remanufacturing for
Marine and Power
Generation
We successfully remanufacture
problems caused by:

Fractures caused by Mechanical damage Eroded water-cooled valve

overheating on third-party seat pockets
arc welding

Erosion in the valve seat pocket can take the pocket beyond
the manufacturer’s last standard oversize.

Cast Iron Welding Services utilises a process known as ‘Gas

Fusion Welding’. We rebuild the entire valve seat chamber
with new material and machine it to accept the manufacturers
standard size valve seats. The rebuilt cover is hydraulically
tested, class approved and returned to the customer
complete and ready to fit
Introduction

Over 30 years ago Cast Iron Welding Services

took the long practiced technique of gas fusion
welding of foundry castings and applied it to
marine engine components. We have developed
a remanufacturing method which has offered an
attractive alternative to the expense of buying a
new part and the risk of buying a second hand one.

For cylinder heads with a combustion face diameter of 200mm or more we are able
to perform a cost effective remanufacturing process which carries the approval of
all major IACS classification societies and is backed by our own 12 month guarantee.
Typically offering savings of 25 to 70 percent against the cost of a new replacement,
our unique process is endorsed and used by some of the world’s largest ship owners
and technical management companies, spare parts suppliers, and major engine
builders. Our gas fusion process can be equally well applied to recover cylinder heads
which are cracked, eroded, severely mechanically damaged, have suffered from
previous badly performed temporary repairs or have simply reached final stage seat
pocket oversizing.

Remanufactured cylinder heads are fitted with appropriate new parts such as valve
seats, valve guides, injector sleeve and guide bolts. Only original or OEM specification
parts are fitted, and a complete rocker side build-up can also be carried out if
required. Following a pressure test we paint your cylinder head in the finish colour of
your choice, protect all bare metal parts against transit and storage corrosion and pack
in a suitable box. Shipment can take place to a warehouse, repair shop, port or vessel
of your choice, wherever they are in the world.

3
Cast Iron Welding Services Marine and Power Generation

Remanufacturing can save

up to 75% of the cost of a new
replacement component.

Step 1 Step 2 Step 3

Dismantled Initial hydraulic test Crack tested

Step 4 Step 5 Step 6

Hydraulically tested to Critical dimensions are A detailed inspection report

10 bar recorded together with a fixed price
quotation is submitted to the
customer for approval

4
castironwelding.co.uk +44(0)1530 811 308

Above A severely damaged cylinder head before and after refurbishment

5
Cast Iron Welding Services Marine and Power Generation

Caterpillar / MaK CM Range of Common defective areas on the CM Range of Caterpillar/

MaK Cylinder Heads are returning the corroded exhaust
Engines CM20, CM25, CM32 and
valve seat pockets to standard size and rebuilding corroded
CM43 Cylinder Head areas in the Exhaust Gas channel

Remanufacturing

Excessive rust corrosion on interior or machined faces Severe mechanical damage to combustion face

Exhaust gas outlet port with corrosion Heavy corrosion to wall of valve seat pocket

Corroded valve seat pockets Completed remanufacture with class certification

1 — 6 MaK Cylinder Head Remanufacture CM20, CM25, CM32 and CM43

6
castironwelding.co.uk +44(0)1530 811 308

Classification approved weld process to condemned MaK – Classification Certification

Cylinder Head. The Standard remanufacturing process – 12 Month Warranty
includes the supply and fitting of standard size valve seats,
valve guides and injector tube. In addition we offer a full re-
build service.

7
Cast Iron Welding Services Marine and Power Generation

Early designs of MAN engines The current designs 32/40, 48/60, 51/60 now incorporate
integral seats with the exhaust being water cooled,
utilised cages to accommodate
CIWS’s extensive experience on all types has enabled the
both inlet and exhaust valves, formulation of a standard ‘Scope of Repair’ highlights of
which includes for rebuilding and returning to standard size
typical types being 40/54, 52/55,
corroded seat pockets, valve cage landings, ‘O’ ring sealing
48/60 and 58/64. locations, cracks and mechanical damage.

1 — 6 This crack between the exhaust bores is a very typical defect corrected
by our process on MAN 58/64 Cylinder Heads

8
castironwelding.co.uk +44(0)1530 811 308

Wartsila 46 Cylinder Head Valve The most common defective area required on the Wartsila
46 Cylinder Head is valve seat replacement, caused by
Seat Pocket Remanufacture
erosion from coolant leaking between the seat and pocket.
When the last oversize seat has been fitted and needs
replacement, the head is no longer serviceable.

Cast Iron Welding Services can rebuild the valve seat pockets, machine them to their original
dimensions and fit standard size valve seats as used on the head when new.

Wartsila 46 Cylinder Head Cross Some Wartsila 46 applications cause the cross bore cooling
channels in the flame plate to corrode, eventually damaging
Bore Cooling Channel
the valve seat pockets. We remove the corroded areas
Remanufacture completely, rebuild the cooling channels and machine them
back to original dimensions.

9
Cast Iron Welding Services Marine and Power Generation

Medium Speed Liquid Fuel and Gas

Engines… Cylinder Head
Remanufacture

The most common problem that we see in our workshop is

corroded Exhaust Valve Seat Pockets.

Pockets rebuilt and restored to standard size.

10
castironwelding.co.uk +44(0)1530 811 308

Various Casting Remanufacture CIWS can carry out high quality restoration to any type,
shape or size of casting , these pictures demonstrate the
varied types of cast iron components we restore on a
daily basis.

11
Cast Iron Welding Services Marine and Power Generation

Technical
Information

Gas fusion welding of cast iron ensures a homogeneous

stress free weld with improved metallurgical and machining
properties compared to those of the parent metal.

All castings are pre-heated at a controlled rate until the

optimum welding temperature is reached. Whilst the entire
component is maintained at this temperature, the area to be
remanufactured is then subject to the application of intense
localised heat bringing it to a fluid state.

The welding operative maintains a molten pool of the

base metal into which is fed a carefully selected, own
manufactured, cast iron filler material at the same grade.

Controlled cooling from the fluid state to ambient

temperature ensures a stress free homogeneous weld
deposit.

These examples of welding sections magnified 105 times

ilustrate the integrity of the weld interference of spheroidal
graphite irons.

Material Testing

Castings are manufactured in several types of material it

is important that before any welding is carried out a full
material analysis should be established.

CIWS have proved with classification that the materials

have been successfully tested and that certification has
been issued for common grades of cast iron.

14
Americas UK / Europe / Rest of World

CIWS México S.A. de C.V. CIWS UK

Ave. San Nicolás 3500 Units 3–5 Samson Road, Hermitage
Col. Residencial Vidriera Industrial Estate, Coalville,
Monterrey, N.L. Leicestershire, LE67 3FP
México, 64508
Telephone

Telephone +44 (0)1530 811 308

+ 52-81-8331-0816
Website

Website www.castironwelding.co.uk
www.ciwsamericas.mx
Contact email

Contact email sales@ciws.co.uk

service@ciwsamericas.mx

 CIWS Americas

 CIWS UK / Europe / Rest of World

UK / Europe / Rest of World

CIWS UK
Units 3–5 Samson Road, Hermitage
Industrial Estate, Coalville,
Leicestershire, LE67 3FP

Telephone

+44 (0)1530 811 308

Website

www.castironwelding.co.uk

Contact email

sales@ciws.co.uk

Americas

CIWS México S.A. de C.V.

Ave. San Nicolás 3500
Col. Residencial Vidriera
Monterrey, N.L.
México, 64508

Telephone

+ 52-81-8331-0816

Website

www.ciwsamericas.mx

Contact email

service@ciwsamericas.mx

Printed February 2020