Casting Defect Patching Compound — Epoxy Metal Repair UAE | KalciteBond

Application Guide · KalciteBond

Casting Defect Patching Compound — Epoxy Metal Repair for Foundry & Machined Parts

KalciteBond Epoxy Metal Putty achieves 22.4 MPa tensile shear strength (CCCS Report ZR268571012, CNAS L24234) — suitable for salvaging shrinkage porosity, cold shuts, and surface defects on cast iron, steel, and aluminium components. Shore D hardness 78 after cure: machinable to drawing tolerance.

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Casting Defects This Compound Repairs

Shrinkage Porosity

Fill voids 0.5–30 mm in cast iron pump housings, valve bodies, and compressor casings. The putty can be stretched 20–30 cm before cure — fills irregular cavity shapes without backing forms.

Cold Shuts & Misruns

Repair incomplete fusion lines on non-critical structural surfaces. Apply to machined faces and cure to Shore D 78 — hard enough to re-machine, file, or grind flush.

Surface Pits & Blow Holes

Cosmetic and dimensional restoration of pit clusters on sealing faces and flanges. Full cure 8.35 h at ambient temperature — no post-cure oven required.

Machining Gouges

Salvage over-machined or tool-damaged surfaces on castings that cannot be re-welded. Tensile shear 22.4 MPa sufficient for static load-bearing restored surfaces.

Wear & Erosion Damage

Rebuild eroded pump impeller hubs, agitator blades, and mixer shafts. Oil resistance 94.6% retention at 72 h maintains bond in lubricated assemblies.

Corrosion Pits on In-Service Parts

Restore corroded sealing grooves and bolt-hole areas without full casting replacement. Water resistance 93.7% retention at 72 h (GB/T 1733-1993).

Verified Performance Data — CCCS / CNAS L24234

Report ZR268571012 · ILAC-MRA signatory · Valid to 2027-02-03

Property Result Casting Repair Relevance
Tensile shear strength 22.4 MPa 49% above GB/T 13553-2018 min.; suitable for static structural surfaces
Shore D hardness (23°C) 78 Machinable, fileable, grindable to drawing tolerance
Surface dry time (25°C) 29 min Reduced scrap-yard dwell time
Full cure 8.35 h Same-day repair and dispatch; no oven post-cure
Oil resistance (72 h) 94.6% retention Stable in lubricated gearboxes and hydraulic environments
Water resistance (72 h) 93.7% retention Suitable for coolant and wash-down environments
Operating temperature −20°C to +80°C Process temperatures across UAE industrial range

Application Procedure

  1. Clean the defect
    Degrease with solvent wipe. Remove loose material by grinding or rotary burr. No grit-blast required; substrate moisture ≤10%.
  2. Undercut if required
    For shallow pits, create a slight mechanical key with a carbide burr (dovetail profile) to improve interlocking.
  3. Mix A+B
    Blend white powder (A) and black paste (B) by hand until uniformly grey. No measuring scale needed for small repairs.
  4. Press into defect
    Work putty firmly into the cavity, eliminating air pockets. Overfill by 1–2 mm to allow for finish grinding.
  5. Surface dry — 29 min
    Tack-free. May be lightly sculpted or scribed for parting-line references.
  6. Full cure — 8.35 h
    Shore D 78 achieved. Part is ready for machining, grinding, or coating.
  7. Finish to tolerance
    Machine, file, or grind flush. Cured compound accepts standard HSS and carbide tooling at low speeds with coolant.

FAQ

Can the cured compound be machined on a lathe or milling machine?

Yes. Shore D 78 hardness allows turning, milling, and grinding with standard carbide tooling. Use low cutting speed (30–50 m/min) and adequate coolant to prevent heat build-up above 80°C.

Is it suitable for pressure-boundary castings (valves, pump bodies)?

For non-critical surfaces and cosmetic/sealing applications, yes. For pressure-boundary defects on PED or ASME B16.34 code components, provide the CCCS/CNAS test report to your project engineer for fitness-for-service assessment.

Does it bond to aluminium castings?

Yes — clean bare aluminium with solvent wipe; light scuff with 80-grit abrasive improves adhesion. No etching primer required.

What sizes are available?

Sample kits: 2 kg. Standard trade units: 5 kg, 10 kg, 25 kg. OEM bulk: 1-tonne pallet. Custom packaging and bilingual EN/AR labels available at no extra charge above 500 kg.

Source Casting Repair Compound Direct from Manufacturer

22.4 MPa CCCS/CNAS certified · Shore D 78 machinable · Non-hazardous · FOB 20 days to UAE · OEM packaging available

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