Electro Motive Diesel EMD

Crankshaft Inspection and preparation for Chrome Plating

Your crankcase is first bathed in hot caustic to clean off all foreign matter. It is then steam cleaned to power out all tiny holes and crevices. Also, any counter weights, temporary repairs or plugs are removed. The crankshaft is now magnetized, then sprayed with a solvent containing fine iron particles. These show fluorescent light to inspect each bearing surface, key way, webbing and radius.

Additional inspections from magnetic particle to ultrasonic are performed periodically as needed throughout the process. A complete written report is prepared and attached to your crankshaft. This compares the shaft with original O.E.M. standards and the report accompanies your crankshaft during restoration. The report is checked at every stage by each job supervisor and is triple-checked by quality assurance inspectors all the way through to completion of salvage and restoration.

After inspection is completed, the crankshaft is ready for pre-grinding for chrome with care taken to their radius of the crankshaft as so not to remove any strength from the parent material. The undersize of the crankshaft before chrome plating depends on application of crankshaft and service that the crankshaft will be in.

 

Crankshaft Shot Peening

All crankshafts are peened whether welded or not. That is, welded shafts are shot peened TWICE. This realigns the molecular structure and improves the tensile, fatigue and heat strength of the forging. The shaft is cleaned of any contaminants. It then goes to be chrome plated.

LARGE CRANKSHAFTS. BECAUSE OF THE SPECIAL NEED AND TENSIONS OF THE LARGE SHAFTS UP TO 28 FEET IN LENGTH COASTAL PLATING HAS DEVELOPED ROTATING SUPPORTS WHICH ASSURE THAT NO MATTER WHAT SIZE, WEIGHT OR CONFIGURATION THE CRANKSHAFT WILL BE RESTORED TO THE ORIGINAL O.E.M. STANDARDS.

Crankshaft GRINDING AND BALANCING

After chrome plating, each surface is individually ground to bring it into precise conformity with written specifications and O.E.M. standards. Coastal Plating machinery- much of it imported from Italy- permits the bearing surfaces and journals to be ground to a tolerance of .0002 of an inch.

After grinding, a final Magnaflux examination is performed to insure no flaws exist in any portion of their crankshaft. The shaft is then dynamically balanced so it will run smoothly without vibration or pounding at ALL operating speeds. Also post grinding, the chrome plated surfaces are lapped and polished to make certain all journals, pulley and gear fits and bolt holes are perfect and meet factory standards. A final inspection is made and the written report is personally checked by Coastal Plating Management.

When the crankshaft repair passes final inspection it is immediately painted with a rust-proof treatment for protection in transit or storage, and prepared for shipment back to your job site. Coastal Plating realizes how vital it is to have your crankshaft repaired right the first time, so you may re-assemble your engine and get going again. For this reason no craftsman, no machine operator, no supervisor will permit the restoration process to continue until each stage of workmanship is PERFECT.

Crankshaft Welding Process

If journals are burned out and reveal cracks, these will be repaired by submerged arc welding. Each radius, stress point, thrust face and journal is carefully examined. Each crack is ground away and welded. We do not weld over cracks no matter how tiny.

LARGE CRANKSHAFTS. BECAUSE OF THE SPECIAL NEED AND TENSIONS OF THE LARGE SHAFTS UP TO 40 FEET IN LENGTH COASTAL PLATING HAS DEVELOPED ROTATING SUPPORTS WHICH ASSURE THAT NO MATTER WHAT SIZE, WEIGHT OR CONFIGURATION THE CRANKSHAFT WILL BE RESTORED TO THE ORIGINAL O.E.M. STANDARDS.

Crankshaft Heat Treatment

Coastal Plating heat treats the crankshaft to relieve any stress that exists in the forging. The crankshaft is baked in our annealing oven at steady temperature for a pre-set period of several hours.

Crankshaft Straightening Service

If necessary, the shaft is straightened by peening, shot peening or both. High spots in the shafts are gauged and removed through this peening. Crankshafts that are excessively bent are heated to 650 F and straightened while hot.

Crankshaft Ultra Sonic Readings

If necessary, the shaft is straightened by peening, shot peening or both. High spots in the shafts are gauged and removed through this peening. Crankshafts that are excessively bent are heated to 650 F and straightened while hot.

Other Electro Motive Diesel Crankshaft Models