WELCOME TO
Metalock Official Partner

ABOUT

METALOCK ENGINEERING HELLAS

After years of experience in Repairs, we chose our collaboration with the accomplices in the field of repair The Metalock International Association Ltd, which is a pioneer in new technologies of repair and maintenance. Main works of our company are Metalock repairs, overhauling of engines, replacements of crankshafts, in situ machining, welding, high pressure hydraulics repair and reconditioning of diesel engine components. In ship repairing our main concern is the safety and satisfaction of the customer which is achieved by constant evolving methods of repair. We have available experienced technicians-engineers, in order to present responsibility and quality. Our engineers have experience of repairs, in many types of Engines. Especially in replacement of major attachments, like Crankshafts and Engine Blocks. Beyond marine repairs we are involved in industrial repairs like mining industries, power plants etc. Furthermore, we are qualified and certified as manufacturers of high precision machine parts suitable for internal combustion engines and auxiliaries.

METALOCK INTERNATIONAL ASSOCIATION

Metalock is a worldwide organization with company-members in almost every country. These are licensed members of The Metalock International Association and use exclusively the Metalock process in every country. The unique Metalock material is the result of continuous research of M.I.A. and is manufactured exclusively for its members. The composition, the forging and placement process of the material is M.I.A.’s exclusiveness. Metalock repair is specialized by trained engineers under the control and license of M.I.A. Annual conferences are held in which each company-member is informed of the latest developments on the Metalock process and exchange technical experience in order that they can deal the problems of its client with diligence and seriousness.

The problem

Breakages on cast iron parts of engines like liners, cylinders, diesel heads, bedplates, bearings and every stressed part of an engine is a serious problem for the engineer that deals with its repair. It is known that by using welding processes (arc welding, oxy-fuel welding) in aforementioned parts is impossible that undesirable effects that are caused by high temperatures in the repaired parts cannot be avoided. The change in the original structure of the metals, distortions and tensions, are the most serious drawbacks of the thermal repairs, and result in less resistance in compression, expansion and stresses of the section that was repaired and thus its breakage once again.

Solution

By using cold stitching Metalock, all aforementioned drawbacks are avoided. Repair takes place in ambient temperature, without the use of flame, stitching fractures utilizing stiching locks (Locks) made of high strength special alloys of different technical and geometrical characteristics, which are inserted transverse to the fracture with the help of high pressure pneumatic tools. The fracture is then filled between the locks with special studs providing stability and water-pressure tighting. In case special reinforcement is needed in stressed parts, high strength alloy inserts (Masterlocks) are inlaid by cold working. Non Destructive Testing (NDT) in the repaired parts takes place after the end of the Metalock process with the use of special testing tools like spray (dye check), magnetic particles and Ultrasonic.

Advantages

Repair with Metalock stitching restores the original stability and water-tighting of the repaired part without altering the structure of the metal. It dampens and absorbs compression stresses. Maintains relieved conditions of internal stresses where the rapture occurred. Distributes load away from fatigue points. The vast majority of Metalock repairs can be done in situ with no need of any dismantling or spadework. No turning and planing is needed after the stitching process is done.



The metalock procedure step-by-step description.


  • STEP 1

    (1) After examination and reporting to the customer, the crack is positioned, aligned and held together firmly with special devices and clamps.(2) Using a drilling jig, groups of holes are drilled perpendicular to the crack up to the tool depth of the casting.

  • STEP 2

    (3) The Metalock key is a special molded part made of a special alloy, whose size and length are fitted to the corres- ponding crack. (4) The holes are linked using a pneumatic chipping hammer and fitted to the shape of the Metalock key. (5) Individual layers of keys are inserted into the openings and caulked into an interlocking form, which is practically integ- rated into the base metal.

  • STEP 3

    (6) Threaded holes are drilled along the crack...


  • STEP 4

    (7) ...and tightened with thread bolts lengthwise. (8) The result is a pressure- tight connection. The casting becomes rigid again.

  • STEP 5

    (9) The Metalock thread bolts play a crucial part in pressure- tight Metalock repairs. (10) The thread bolts are tur- ned in until the heads are sheared off. The remaining metal is removed with a pres- sure chisel,

  • STEP 6

    (11) following by grinding, polishing.

Our Projects

Stitching of smelting furnace casing and gear

Stitching of various piston liners

Stitching of Block Aux/E Man B&W STX 28/32 H

Stitching of Aux/E DAIHATSU DK

Stitching of Block Aux/E Man

Stitching of Block Aux/E Yanmar and rebuild of crankcase door

Stitching of gearbox casing

Stitching of Block Aux/E DAIHATSU 6DK- 20

Stitching of Block Aux/E Yanmar N18L

Stitching of FLENDER gearbox

Stitching of Block Aux/E Yanmar

Stitching of Block M/E MAK 9M 453AK

Stitching of Aux/E cylinder cover

Welding of cast steel gearbox casing with special electrodes

Welding of gearbox casing with special electrodes

Stitching of Generator Engine Type HIMSEN H21/32

Burned Crankshaft replacement on Engine type 9L27/38

Crankshafts replacement on Generator Engine type YANMAR 6N280L - GN X

No 1 Diesel Generator, Crankshaft replaced with new one

Contact 24/7

Metalock Engineering Hellas

E. Katsandris & Co G.P.
Branch : E.K. Metalock Cyprus Engineering Limited