Cold repairs of fractured castings

Abstract

The project deals with a repair method for cast iron components which is a suitable alternative to welding. The advantages of this repair method, which is called the metal key repair process, over welding are pointed out and confirmed by the results of the tests carried out. The following testing modes are dealt with: a) Tensile tests on parent metal, repaired and key specimens. welded, metal key b) Fatigue tests on metal key repaired and welded specimens. c) Hardness tests on the keys. d) Pressure tests on welded and metal key repaired specimens. e) Photoelastic stress analysis on metal key repaired specimens. The Metalock repair process, one type of metal key repair processes and also the method used to repair the specimen, is explained in detail while other processes are also explained. A comparison between welding and the metal key repair process as regards the cost of a repair, especially due to downtime and loss in production, of the two processes. A few practical cases of the metal key repair process are also described.