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Irontite Products Inc. Crack Detection & Repair Manual
Introduction

The Irontite crack repair system is a cold repair process for repairing cracks in castings by adding metal and
moving the metal in the casting to close the crack.
The basic crack repair process involves:
1. Detection of the crack - including determining the location of the crack.
2. Relieving the stress in the casting in the area of the crack.
3. Adding and moving metal in such a manner as to close off the crack.
4. Refinishing the surface of the repaired casting.
This cold crack repair process does not in any way subject the casting to high temperatures of a welding
process, nor does it alter the heat treated characteristics of the casting.
Cracks in metal castings are the result of stress or strain in some part of the casting. This stress or strain finds
a weak point in that section of the casting and causes the casting to separate at the weak point.
Such stress or strain may develop from:
1. The casting having been subjected to pressure or temperature changes before it was properly aged,
or
2. Having been subjected to excessive heat or cold, or
3. Subjected to too rapid a change in the temperatures.
Whatever may have caused the stress, and in turn the crack, the important job is to relieve the stress at the
point of the crack, close off the crack and resurface the casting.

The first step in the repair process is detecting the crack.
Detection of the crack involves not only finding that a crack exists, but also determining its exact location and
marking the entire crack for subsequent repair.
The cracks may be detected:
1. By using a magnet and magnetic powder for ferrous materials,
2. By the use of dye penetrant, or
3. By pressurizing the head or block with a pressure tester and applying a bubble solution.

Magnetic Crack Detection
Electro Magnet
Each Kit Contains:
The Power-Pak Electro Magnet, 115V or 230V
1-Pound can of Magnetic Powder
Powder Spray Bulb
Handy Tool Box

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