Metalock Brasil completes cold repair on merchant vessel flywheel gear

Metalock Brasil has carried out a cold structural repair on the flywheel gear of the main engine of an international-flagged merchant vessel, restoring a critical component of the engine starting system without the need for replacement. The damage, identified during inspection, measured about 300mm in length and affected three gear teeth.
Engineers conducted a shipboard assessment, including detailed visual inspection and preparation of a mould for a custom insert. The team then manufactured the insert in SAE 1045 carbon steel at its workshop before returning to the vessel to remove the damaged section, clean the area and prepare the surface for installation.
Technicians installed the insert using the Metalock cold repair process, applying metal keys, fixing bolts and master locks to provide mechanical anchoring and restore structural strength. After installation, the team carried out manual finishing using a jig referenced to the intact teeth to re-establish the original gear profile and correct alignment.
Following completion, the vessel’s technical staff performed a visual inspection on board. Once the starter motor arrived, operational tests were completed and approved by the client, clearing the equipment for service. The repair avoided component replacement, reduced downtime and returned the engine to operation with restored reliability.