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US2537533A - Method of repairing cracks in castings - Google Patents

Method of repairing cracks in castings Download PDF

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Publication number
US2537533A
US2537533A US716691A US71669146A US2537533A US 2537533 A US2537533 A US 2537533A US 716691 A US716691 A US 716691A US 71669146 A US71669146 A US 71669146A US 2537533 A US2537533 A US 2537533A
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Prior art keywords
crack
plugs
casting
metal
repairing
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US716691A
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Gerald E Ingalls
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K1/00Soldering, e.g. brazing, or unsoldering
    • B23K1/20Preliminary treatment of work or areas to be soldered, e.g. in respect of a galvanic coating
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23PMETAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P6/00Restoring or reconditioning objects
    • B23P6/04Repairing fractures or cracked metal parts or products, e.g. castings
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/49Method of mechanical manufacture
    • Y10T29/49718Repairing
    • Y10T29/49732Repairing by attaching repair preform, e.g., remaking, restoring, or patching
    • Y10T29/49742Metallurgically attaching preform
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/49Method of mechanical manufacture
    • Y10T29/49718Repairing
    • Y10T29/49748Repairing by shaping, e.g., bending, extruding, turning, etc.
    • Y10T29/4975Repairing by shaping, e.g., bending, extruding, turning, etc. including heating

Definitions

  • the present invention relates to improvements in methods for repairing castings and more specifically refers to an improved method for repairing breaks in castings such as cylinder blocks of internal combustion engines.
  • a further object of the present invention is to accomplish the above mentioned repair without the conventional excessive heat treatment or annealing of the complete cylinder block or casting.
  • Figure l is a fragmentary plan View of the conventional internal combustion engine cast cylinder block showing break or crack in the said cylinder.
  • Figure 2 is a fragmentary section view out longitudinally through the cracked section and showing the insertion of a plug.
  • Figure 3 is also a fragmentary section view cut longitudinally through the cracked section and showing the plug inserted and mechanically welded before brazing.
  • Figure 4 is a sectional view as mentioned above and showing the completed mechanical weld.
  • This operation mechanically forces the break closed and is so facilitated by the preheating which makes the metal soft and prevents further breakin when the plugs are inserted.
  • This peening or mechanical welding step is followed by a heat treating operation combined with a brazing operation or by a heat treating operation without brazing along the break, so as to fuse the metal into a solid mass as well as fuse the casting metal and the inserted plugs. Any suitable or conventional brazing method is satisfactory.
  • This operation seals up and fuses the break as indicated-by numeral 4 of Figure 4.
  • the composition of the plug inserts depend upon the type of metallic casting to be repaired. Copper or copperized iron plugs have proved satisfactory in repairing the cylinder block casting of the conventional internal combustion engine. The above recited method for repairing casting breaks or cracks is satisfactory for merely a straight crack or a radial break. It is a simple and economical means of repairing casting breaks.
  • Method of repairing a crack in a casting comprising heating the area of the casting along the. crack so as to soften the metal thereof, then driving tapered fusible metal plugs into the crack in close side by side relation along the crack, then peening the edges of the crack onto the plugs, and then heating the resultant so as to fuse the plugs conformably in place in a manner to fill the crack, and brazing said resultant so as to cover the plugs and the peened edges of the crank so as to seal the filled crack.
  • Method of repairing a crack in a metal casting comprising heating the area of the crack sufficiently to soften the metal, driving tapered fusiblemetal plugs into the crack in side by side positions along the crack and peening the edges of the crack upon the plugs while the metal is still soft from the heating, said plugs being driven withsufficient force to produce conforming and intimate association of the plugs and the sides of the crack and said peenin of the edges Of the crack..']geing sufficient to maintain the driven plugs in place, and then reheating the area of the crack suiiiciently to fuse the plugs to fill the crack.
  • Method of repairing a crack in a metal casting comprising heating the area of the crack sufficiently to soften the metal, driving tapered fusible rnetal plugs into the crack in side by side positions along the crack and peening the edges of the crack upon the plugs while the metal is still soft from the.
  • said plugs being driven with suflicient force to produce conforming and intimate association of the plugs and the sides of the crack and said peening of the edges of the crack being sufficient to maintain: the: drivenplugs in place, and then reheating the area of the crack sufiiciently to fuse the plugs, to fill the crack,'saicl reheating being accompanied bybraze ing of the plugs and peenect edgtsvoj'the-crack together in a manner to seal the crack.
  • Method of repairing a crack in a casting comprisingheating the area of the casting along the crack so-as; to soften the metal thereof, pro-- cmring ta-pered fusible metal'plugs atzleast as wide as the crack, then inserting the smaller ends of said plugs into the crack in closely spaced side by side relation along the crack and driving the plugs further into the crack so as to partly fill the crack, then peening the edges of the crack onto the plugs, and then heating the resultant so as tofuse the plugs conformably in place so as to fill the crack.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Cylinder Crankcases Of Internal Combustion Engines (AREA)

Description

Jan. 9, 1951 G. E. INGALLS 2,537,533
METHOD OF REPAIRING CRACKS IN CASTINGS Filed Dec. 17, 1946 62 0110 ive: an; I
a e I i Patented Jan. 9, 19 51 METHOD OF REPAIRING CRACKS IN CASTING S Gerald E. Ingalls, 'lndianapolis, Ind. Application December 17, 1946, Serial No. 716,691
The present invention relates to improvements in methods for repairing castings and more specifically refers to an improved method for repairing breaks in castings such as cylinder blocks of internal combustion engines.
Cracked castings have presented considerable repair problems especially in that when castings are repaired by conventional welding methods it is necessary to remove the cylinder block casting from the remainder of the engine inorder to heat treat the casting prior to welding. This operation is cumbersome, time consuming, and expensive, and the above method has not proved generally satisfactory in all cases.
It is an object of this invention to do away with the above difficulties and to provide a method whereby a casting or cylinder which has been cracked can be repaired without requiring the removing of the cylinder block from the engine.
A further object of the present invention is to accomplish the above mentioned repair without the conventional excessive heat treatment or annealing of the complete cylinder block or casting.
Further objects and advantages of my invention will be apparent from the following detailed description and claims taken in conjunction with the annexed drawings wherein like parts are indicated by like reference numerals and Where:
Figure l is a fragmentary plan View of the conventional internal combustion engine cast cylinder block showing break or crack in the said cylinder.
Figure 2 is a fragmentary section view out longitudinally through the cracked section and showing the insertion of a plug.
Figure 3 is also a fragmentary section view cut longitudinally through the cracked section and showing the plug inserted and mechanically welded before brazing. I
Figure 4 is a sectional view as mentioned above and showing the completed mechanical weld.
Referrin now in detail to the accommpanying drawings and more specifically to Figure 1,
which illustrates an internal combustion engine cylinder block having a break or crack i. In my method of repairing such casting breaks, the general area of the break is heat treated with a torch of suitable nature in order that the metal casting may be annealed in and around the general area of the break. This operation i followed by the insertion of metallic tapered circular plugs 2 into the break or crack I ata distance relatively close together. Following the insertion of the aforementioned plugs both edges 4 Claims. (Cl. 29148) of the break are peened with a peening tool or a round headed punch and hammer so as to close the said break around the plugs and as indicated by the numeral 3. This operation mechanically forces the break closed and is so facilitated by the preheating which makes the metal soft and prevents further breakin when the plugs are inserted. This peening or mechanical welding step is followed by a heat treating operation combined with a brazing operation or by a heat treating operation without brazing along the break, so as to fuse the metal into a solid mass as well as fuse the casting metal and the inserted plugs. Any suitable or conventional brazing method is satisfactory. This operation seals up and fuses the break as indicated-by numeral 4 of Figure 4.
The composition of the plug inserts depend upon the type of metallic casting to be repaired. Copper or copperized iron plugs have proved satisfactory in repairing the cylinder block casting of the conventional internal combustion engine. The above recited method for repairing casting breaks or cracks is satisfactory for merely a straight crack or a radial break. It is a simple and economical means of repairing casting breaks.
It is apparent that many deviations from my method may be accomplished without departing from the scope and spirit of my invention, I therefore do not limit myself to the specific examples herein set forth.
What I claim as my invention is:
1. Method of repairing a crack in a casting comprising heating the area of the casting along the. crack so as to soften the metal thereof, then driving tapered fusible metal plugs into the crack in close side by side relation along the crack, then peening the edges of the crack onto the plugs, and then heating the resultant so as to fuse the plugs conformably in place in a manner to fill the crack, and brazing said resultant so as to cover the plugs and the peened edges of the crank so as to seal the filled crack.
2. Method of repairing a crack in a metal casting comprising heating the area of the crack sufficiently to soften the metal, driving tapered fusiblemetal plugs into the crack in side by side positions along the crack and peening the edges of the crack upon the plugs while the metal is still soft from the heating, said plugs being driven withsufficient force to produce conforming and intimate association of the plugs and the sides of the crack and said peenin of the edges Of the crack..']geing sufficient to maintain the driven plugs in place, and then reheating the area of the crack suiiiciently to fuse the plugs to fill the crack.
3. Method of repairing a crack in a metal casting comprising heating the area of the crack sufficiently to soften the metal, driving tapered fusible rnetal plugs into the crack in side by side positions along the crack and peening the edges of the crack upon the plugs while the metal is still soft from the. heating, said plugs being driven with suflicient force to produce conforming and intimate association of the plugs and the sides of the crack and said peening of the edges of the crack being sufficient to maintain: the: drivenplugs in place, and then reheating the area of the crack sufiiciently to fuse the plugs, to fill the crack,'saicl reheating being accompanied bybraze ing of the plugs and peenect edgtsvoj'the-crack together in a manner to seal the crack.
4. Method of repairing a crack in a castingcomprisingheating the area of the casting along the crack so-as; to soften the metal thereof, pro-- cmring ta-pered fusible metal'plugs atzleast as wide as the crack, then inserting the smaller ends of said plugs into the crack in closely spaced side by side relation along the crack and driving the plugs further into the crack so as to partly fill the crack, then peening the edges of the crack onto the plugs, and then heating the resultant so as tofuse the plugs conformably in place so as to fill the crack.
GERALD E; IN GALLS.
REFERENCES CITED The following references are of record in the file: ofthis patent:
UNITED STATES PATENTS Number Name Date 1,322,245 Klassen Nov. 18, 1919 1,384,456. Eury July 12, 1921 2 ,301,513 Brewer Nov. 10, 1942 2,361,106 Jensen Oct. 24, 1944 2,351,701 Michael's Oct. 31, 1944 2,369,415 Sherman Feb. 13, 1945

Claims (1)

1. METHOD OF RAPAIRING A CRACK IN A CASTING COMPRISING HEATING THE AREA OF THE CASTING ALONG THE CRACK SO AS TO SOFTEN THE METAL THEREOF, THEN DRIVING TAPERED FUSIBLE METAL PLUGS INTO THE CRACK IN CLOSE SIDE BY SIDE RELATION ALONG THE CRACK, THEN PEENING THE EDGES OF THE CRACK ONTO THE PLUGS, AND THEN HEATING THE RESULTANT SO AS TO FUSE THE PLUGS CONFORMABLY IN PLACE IN A MANNER TO FILL THE CRACK, AND BRAZING SAID RESULTANT SO AS TO COVER THE PLUGS AND THE PEENED EDGES OF THE CRANK SO AS TO SEE THE FILLED CRACK.
US716691A 1946-12-17 1946-12-17 Method of repairing cracks in castings Expired - Lifetime US2537533A (en)

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Cited By (21)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2711012A (en) * 1949-09-13 1955-06-21 Hal W Harman Method of repairing cracked casting
US3445914A (en) * 1966-04-18 1969-05-27 Chrome Plate Inc Method of repairing aircraft cylinder heads
US3464103A (en) * 1967-07-13 1969-09-02 Cleon B Harris Method of repairing cracked metallic castings
US3487530A (en) * 1967-10-09 1970-01-06 Abex Corp Method of repairing casting defects
EP0024142A1 (en) * 1979-07-31 1981-02-25 Chromalloy American Corporation Method for repairing a crack in a superalloy material and an article when so repaired
US4638743A (en) * 1985-07-18 1987-01-27 Railcar Specialties, Inc. Method of reinforcing a covered hopper car hatch
US5050385A (en) * 1982-10-06 1991-09-24 Hitachi, Ltd. Inner cylinder for a gas turbine combustor reinforced by built up welding
US6003755A (en) * 1997-02-20 1999-12-21 Lockheed Martin Corp. Method for repair welding aluminum-lithium alloys
US6171415B1 (en) 1998-09-03 2001-01-09 Uit, Llc Ultrasonic impact methods for treatment of welded structures
US20040238508A1 (en) * 2003-05-27 2004-12-02 Rabinovich Joshua E. Low heat input laser component repair or joining with feedstock having conforming surfaces with a substrate
US20050122915A1 (en) * 2003-12-05 2005-06-09 Yazaki Corporation Communication apparatus
US20050145306A1 (en) * 1998-09-03 2005-07-07 Uit, L.L.C. Company Welded joints with new properties and provision of such properties by ultrasonic impact treatment
US20060016858A1 (en) * 1998-09-03 2006-01-26 U.I.T., Llc Method of improving quality and reliability of welded rail joint properties by ultrasonic impact treatment
US20070040476A1 (en) * 2005-08-19 2007-02-22 U.I.T., Llc Oscillating system and tool for ultrasonic impact treatment
US20070068605A1 (en) * 2005-09-23 2007-03-29 U.I.T., Llc Method of metal performance improvement and protection against degradation and suppression thereof by ultrasonic impact
US20070244595A1 (en) * 2006-04-18 2007-10-18 U.I.T., Llc Method and means for ultrasonic impact machining of surfaces of machine components
US7301123B2 (en) 2004-04-29 2007-11-27 U.I.T., L.L.C. Method for modifying or producing materials and joints with specific properties by generating and applying adaptive impulses a normalizing energy thereof and pauses therebetween
US7344609B2 (en) 1998-09-03 2008-03-18 U.I.T., L.L.C. Ultrasonic impact methods for treatment of welded structures
US20080160337A1 (en) * 2006-10-17 2008-07-03 Rolls-Royce Plc Component joining
US7431779B2 (en) 1998-09-03 2008-10-07 U.I.T., L.L.C. Ultrasonic impact machining of body surfaces to correct defects and strengthen work surfaces
US20230108587A1 (en) * 2021-10-04 2023-04-06 General Electric Company Backwall strike braze repair

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1322245A (en) * 1919-11-18 Method oe repairing cylinders
US1384456A (en) * 1919-05-01 1921-07-12 Zebulon J Eury Method of repairing scored cylinders
US2301513A (en) * 1941-04-08 1942-11-10 Brewer Harry Method of repairing cracked machine parts
US2351701A (en) * 1941-11-11 1944-06-20 Cecil J Perkins Process and apparatus for spot-dyeing skeins
US2361106A (en) * 1940-11-04 1944-10-24 Charles A Jensen Method of repairing and for preventing cracks in metal castings
US2369415A (en) * 1943-10-05 1945-02-13 Edgar B Sherman Method of repairing cracked cylinder heads and blocks

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1322245A (en) * 1919-11-18 Method oe repairing cylinders
US1384456A (en) * 1919-05-01 1921-07-12 Zebulon J Eury Method of repairing scored cylinders
US2361106A (en) * 1940-11-04 1944-10-24 Charles A Jensen Method of repairing and for preventing cracks in metal castings
US2301513A (en) * 1941-04-08 1942-11-10 Brewer Harry Method of repairing cracked machine parts
US2351701A (en) * 1941-11-11 1944-06-20 Cecil J Perkins Process and apparatus for spot-dyeing skeins
US2369415A (en) * 1943-10-05 1945-02-13 Edgar B Sherman Method of repairing cracked cylinder heads and blocks

Cited By (26)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2711012A (en) * 1949-09-13 1955-06-21 Hal W Harman Method of repairing cracked casting
US3445914A (en) * 1966-04-18 1969-05-27 Chrome Plate Inc Method of repairing aircraft cylinder heads
US3464103A (en) * 1967-07-13 1969-09-02 Cleon B Harris Method of repairing cracked metallic castings
US3487530A (en) * 1967-10-09 1970-01-06 Abex Corp Method of repairing casting defects
EP0024142A1 (en) * 1979-07-31 1981-02-25 Chromalloy American Corporation Method for repairing a crack in a superalloy material and an article when so repaired
US5050385A (en) * 1982-10-06 1991-09-24 Hitachi, Ltd. Inner cylinder for a gas turbine combustor reinforced by built up welding
US4638743A (en) * 1985-07-18 1987-01-27 Railcar Specialties, Inc. Method of reinforcing a covered hopper car hatch
US6003755A (en) * 1997-02-20 1999-12-21 Lockheed Martin Corp. Method for repair welding aluminum-lithium alloys
US20060016858A1 (en) * 1998-09-03 2006-01-26 U.I.T., Llc Method of improving quality and reliability of welded rail joint properties by ultrasonic impact treatment
US20050145306A1 (en) * 1998-09-03 2005-07-07 Uit, L.L.C. Company Welded joints with new properties and provision of such properties by ultrasonic impact treatment
US6171415B1 (en) 1998-09-03 2001-01-09 Uit, Llc Ultrasonic impact methods for treatment of welded structures
US7431779B2 (en) 1998-09-03 2008-10-07 U.I.T., L.L.C. Ultrasonic impact machining of body surfaces to correct defects and strengthen work surfaces
US7344609B2 (en) 1998-09-03 2008-03-18 U.I.T., L.L.C. Ultrasonic impact methods for treatment of welded structures
US20040238508A1 (en) * 2003-05-27 2004-12-02 Rabinovich Joshua E. Low heat input laser component repair or joining with feedstock having conforming surfaces with a substrate
US7600666B2 (en) * 2003-05-27 2009-10-13 Rabinovich Joshua E Repair with feedstock having conforming surfaces with a substrate
US20050122915A1 (en) * 2003-12-05 2005-06-09 Yazaki Corporation Communication apparatus
US7301123B2 (en) 2004-04-29 2007-11-27 U.I.T., L.L.C. Method for modifying or producing materials and joints with specific properties by generating and applying adaptive impulses a normalizing energy thereof and pauses therebetween
US20080035627A1 (en) * 2005-08-19 2008-02-14 Uit L.L.C. Oscillating system and tool for ultrasonic impact treatment
US7276824B2 (en) 2005-08-19 2007-10-02 U.I.T., L.L.C. Oscillating system and tool for ultrasonic impact treatment
US20070040476A1 (en) * 2005-08-19 2007-02-22 U.I.T., Llc Oscillating system and tool for ultrasonic impact treatment
US20070068605A1 (en) * 2005-09-23 2007-03-29 U.I.T., Llc Method of metal performance improvement and protection against degradation and suppression thereof by ultrasonic impact
US20070244595A1 (en) * 2006-04-18 2007-10-18 U.I.T., Llc Method and means for ultrasonic impact machining of surfaces of machine components
US20080160337A1 (en) * 2006-10-17 2008-07-03 Rolls-Royce Plc Component joining
US8066173B2 (en) * 2006-10-17 2011-11-29 Rolls-Royce Plc Component joining
US20230108587A1 (en) * 2021-10-04 2023-04-06 General Electric Company Backwall strike braze repair
US11951557B2 (en) * 2021-10-04 2024-04-09 General Electric Company Backwall strike braze repair

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