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7/28/2019 Aluminum Crack Inspection and Repair Examples
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Aluminum Crack RepairAluminum Crack Repair
WithoutWithout WeldingWelding
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TopicsTopics
Crack detection/inspection Metal stitching
Threaded hole repair
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Crack DetectionCrack Detection
Visual Pressure testing
Dye-penetrant
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VisualVisual
Practiced by many asthe only way of
finding cracks.
You wouldnt inspectcast iron this way.
Inconclusive.
You cannot find the
ends of the crack.
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After DyeAfter Dye--Penetrant InspectionPenetrant Inspection
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Pressure TestingPressure Testing
Only shows crackthat leak.
Helps determine
the extent of therepair needed.
Must be done
following any
repair.
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DyeDye--PenetrantPenetrant
Cleaner
Penetrant
Developer
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CleanerCleaner
Do not use to cleanthe test area.
Do not spray
directly on the testarea.
Spray only on a dry
shop towel or other
clean cloth.
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PenetrantPenetrant Use small amount.
Can be applied withbrush.
Messy, difficult toremove.
You must wipe as
much as possible offbefore applying thedeveloper.
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Applying Penetrant With aApplying Penetrant With a
BrushBrush
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DeveloperDeveloper
Test area must bewiped clean ofpenetrant byapplying cleaner tothe cloth beforeapplying developer.
Apply developer asdry as possible. Usecompressed air tospeed drying process.
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Step by step procedure
1
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Step by step procedure
2Wait 5 minutes
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Apply cleaner to clean cloth
3
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Wipe off all visible penetrant
4
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Keep cleaning until all
penetrant is gone
5
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Spray on developer very dry
6
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Use compressed air to
accelerate drying
7
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Wait 1 minute before
inspecting
8
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Metal StitchingMetal Stitching
oror
Cold RepairCold Repair
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ObjectiveObjective
1. Stop leaks
2. Prevent crack propagation
3. Structural integrity
4. Prevent seats from coming out
5. Remove the crack for cosmetic reasons
6. $$$
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TwoTwo TypesTypes
ofofStitching PinsStitching Pins
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StandardStandard Threaded PinsThreaded Pins
Straight thread L Seriespins
Seal by interference fit ofthe threads
Exert spreading pressure
For sealing, seat retentionand crack removal
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CASTMASTERCASTMASTER Threaded PinsThreaded Pins
Spiralhook threads
Radial drawing forccreates structural
integrity Not used for seatretention
Seal leaks Prevent crack
propagation
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Working With AluminumWorking With Aluminum
Requires cutting fluid for drilling and tapping. Galls easily.
Cuts easier than cast iron.
Very easy to oversize and egg-shape drilled holes.
Aluminum stitching pins are required in
combustion chambers of cylinder heads. Steel pins can be used for structural repairs.
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Cylinder HeadsCylinder Heads
Many cracks can be repaired withoutremoving the seat inserts by using L Series
pins. Do not drill into water if the crack does not
leak. When the crack does leak you must install
pins under and behind the seat to stop the
leak.
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Cylinder HeadsCylinder Heads
Only when the crack goes between two seats
can you use a steel pin.
Cracks on the top side and between
cylinders on the deck surface require
CASTMASTER pins for structuralintegrity.
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Ford Escort cylinder headFord Escort cylinder head
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Crack over exhaust portCrack over exhaust port
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Install C1 CASTMASTERInstall C1 CASTMASTER
stitching pinstitching pin
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Install L Series pinInstall L Series pin
intersecting the seat insertintersecting the seat insert
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Install L Series pin into theInstall L Series pin into the
floor of the water holefloor of the water hole
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Finished repairFinished repair
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Stitching Pin SelectionStitching Pin Selection
Most aluminum cyl heads have fairly thin walls so
you should use L4 pins that have very fine threads
The fine threads also work well when tapping into
the hard seat insert. L4 pins will fit in between the seats in most cases.
Larger diameter pins are used when the casting is
thicker.
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Structural RepairStructural Repair
UsingUsingCASTMASTERCASTMASTER
Stitching PinsStitching Pins
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InspectionInspection
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Drill the first holeDrill the first hole
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Spotface the holeSpotface the hole
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Apply tapping fluidApply tapping fluid
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Tap the holeTap the hole
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Apply thread sealantApply thread sealant
I t ll C1A l iI t ll C1A l i
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Install a C1A aluminumInstall a C1A aluminum
CASTMASTER stitching pinCASTMASTER stitching pin
Th h d f th i t i t ffTh h d f th i t i t ff
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The head of the pin twists offThe head of the pin twists off
when tightwhen tight
G i d ff h ldG i d ff h ld
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Grind off excess shoulderGrind off excess shoulder
close to flushclose to flush
D ill th t i li htlD ill th t i li htl
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Drill so that pins slightlyDrill so that pins slightly
overlapoverlap
C ti i t lli i tilContinue installing pins until
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Continue installing pins untilContinue installing pins until
the crack is removedthe crack is removed
G i d i fl h dGrind pins flush and peen
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Grind pins flush and peenGrind pins flush and peen
lightly with a needle scalerlightly with a needle scaler
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Completed RepairCompleted Repair
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Pressure test to 40 PSIPressure test to 40 PSI
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Advantages Over WeldingAdvantages Over Welding
Faster Very cost effective
No distortion
Will not anneal the surrounding aluminum
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Advantages of Welding OverAdvantages of Welding Over
StitchingStitching
Welding can repair erosion and electrolysisdamage.
Welding can add reinforcement by adding
material to weak areas such as around headbolt holes.
Welding can replace missing pieces. Welding can build up bearing bores.
OthOther Al i C tiAluminum Castings
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OtherOtherAluminum CastingsAluminum Castings
That Can Be Repaired byThat Can Be Repaired byStitchingStitching
9Aluminum oil pans for Cummins, Cat
and other diesel engines
9Water cooled marine manifolds
9Bell housings and transmission cases
9Engine blocks and intake manifold
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LOCK-N-STITCH Inc.1015 S. Soderquist Rd
Turlock, CA 95380
800-736-8261209-632-2345
www.locknstitch.com
Email for technical support