Metal Repair & Rebuilding

Rotating gear fails at the surfaces that carry the load. Erosion-corrosion and cavitation reshape impeller vanes and casing profiles, pulling a pump off its head curve and cutting efficiency. AAS rebuilds the vane geometry and casing wear areas, then applies a smooth coating to restore the hydraulic profile, so efficiency returns with no rebalancing for weld heat. On shafts, keyway hammering and journal scoring leave the press-fit oversized and the journal undersized for its sleeve. We rebuild journals and keyways cold, then machine back to the specified diameter, with no arc-weld distortion on a slender rotor.

Bearing bores, bushing seats, and vibration-loosened housings shift the rotating axis and shorten coupling and seal life. AAS rebuilds the bore and retainer surfaces and re-chocks the housing to alignment, so the bearing seats to spec without OEM shop rework. Compressor, engine, and gearbox housings carry the same story at their bearing bores and split lines. Bore wear, split-line distortion, and oil-leak paths at the gasket faces retire a housing before the internals are spent. We rebuild bores and split lines cold and machine them flat, and the housing returns to service inside the same outage rather than the OEM lead time. Supporting Belzona 1000 Series metal composites carry the load through these rebuilds.

Flange faces and vessel walls are where small defects become leaks. Heat cycling, gasket-witness machining, and dropped tools deform flange faces and corrode nozzle sleeves, and the line leaks and stays out of service. AAS rebuilds the face against the mating flange using a release agent, so the repaired surface mirrors the mating flange exactly and the spool stays in the line. On heat exchangers, dissimilar tube metals set up galvanic corrosion at the tube sheet and water box, attacking the steel around each tube end. We rebuild and electrically isolate the joint with ceramic-filled epoxies inside the turnaround window, with no hot work, and the bundle returns to service quickly.

Cracks, holes, and general metal loss on pressure equipment are where welding hurts most. On separators and code-stamped vessels, AAS cold-bonds the structural repair and machines it back to dimension, and the fix qualifies as a non-welded repair under the relevant inspection codes such as ASME PCC-2 and ISO 24817. Where corrosion, erosion, or pitting has wasted a surface toward a code-trigger thickness, we rebuild it with cold-cure metal composites and machine to the original tolerance, leaving no heat-affected zone. Valve bodies get the same treatment: eroded body cavities and bonnet faces rebuilt cold, then overcoated with an erosion-resistant layer, so the valve is restored without cutting it out for welding.

Not every repair starts from a known part. Catalog replacements rarely match the dimension a worn assembly actually needs, and welding to join or fabricate metal introduces its own distortion. AAS bonds metal to metal cold and casts replacement parts, gasket seals, and support pads directly against the actual mating surface, with no molds and no hot work. The same approach restores rotating equipment efficiency where flow-induced metal loss has exposed fresh steel for the process chemistry to attack. We rebuild the worn surface and overcoat it with an erosion-corrosion-resistant layer, so pumps, fans, and turbines recommission on their design curve during the same outage.

Every one of these repairs is built around the same outcome. The unit goes back in service without the cost and schedule of replacement or welding. No hot-work permit, no stress relief on a code-stamped vessel, no heat distortion on a slender shaft, and no waiting on an OEM casting. Pumps and rotating gear return to their rated efficiency, sealing surfaces hold, and pressure boundaries pass inspection as non-welded repairs.

The practical payoff is downtime avoided and asset life extended. A housing, bundle, or spool that would otherwise sit idle through a lead time is back online inside the existing outage, often the same shift the crew finishes machining. With 24-hour on-call coverage across Louisiana and a climate-controlled shop for components that come to us, AAS keeps the repair on your schedule, not the supply chain's. Louisiana refiners, petrochemical producers, and marine operators use this to defer capital replacement and keep equipment in service well past the point a corroded surface would normally retire it.