Tungsten Carbide Carbon Coating for Bearings

When it comes to metal surface coating, Tungsten Carbide (WC) is one of the most durable elements which can be used in bearings to offer numerous benefits to both machinery and bearings which are critical for optimal working. To help you know more, This blog covers everything about Tungsten Carbide Carbon Coating for Bearings in detail.   There are a lot of challenges that industries face on day to day basis related to machinery such as overhauling, wear and tear, abrasions, breakdowns, etc. Since machinery has to be operated in an optimum manner to deliver expected results, the bearings should be capable to withstand challenges without any interruptions to ensure optimum performance. To offer extra protection to bearings and increase their service life to work under harsh mechanical environments, NEI provides Tungsten Carbide Carbon Coating (WC/C) on Large Dia Bearings (LDB).  

Understanding Frequent Problems in Industrial Machinery Applications

Machinery applications are often subject to a variety of problems, some of which are more frequent than others. Understanding the root cause of these problems can help to avoid them in the future:  
  • Paper Industry: Calandar Machine

The Calandar Machine in the paper industry may face challenges in very wide load range and zero load situations. It can create problems like micro welding, sliding, and smearing damage.
  • Hydraulic Applications: Pumps and Motors

The pumps and motors may face challenges such as low viscosity lubrication which can create problems like wear-tear and friction.
  • Power Plant: Coal Pulveriser

Coal pulverizers in power plants may face challenges due to contamination and vibration with low-viscosity lubrication. It can create problems like abrasions, Micropitting, smearing, etc.  

Solutions: How Tungsten Carbide Carbon Coating Solve Challenges

WC/C Coating on rolling elements helps in withstanding wear and tear and other critical issues due to the nature of composition which is harder than metal-containing amorphous carbon coating. Here are some of the salient features of Tungsten Carbide Carbon Coating for bearings:  
    1. Thin Coating: Tungsten Carbide Carbon Coating features a very thin coating of 1-2 ?m.
    2. High Adhesion Strength: Adhesive strength is important because it allows bonding with surfaces securely which makes the bearing work as usual without resulting in breakdown due to angular misalignments.
  • High Hardness: It helps in better surface contact between the components and increase the service life of bearings without wear and tear thus helping machinery components to work well.

Technical Aspects of Tungsten Carbide Carbon Coating

The Tungsten Carbide Carbon Coating offers improved bearing performance in terms of wear resistance under extreme working conditions. This is possible due to the hard coating on the rolling element which polishes the racing surface whereas the carbon layer offers lubrication for smooth performance. It promotes low friction and eliminates problems related to smearing and wear and tear which increases service life.  

Why Tungsten Carbide is a Reliable Material for Bearings Coating

Tungsten Carbide is an extremely hard ceramic material that comes in the form of grey fine powder particles. This material is known for its high resistance to wear, abrasion, and scratching, making it an ideal shield against surface damage from attacks like corrosion, erosion, and fatigue. Ceramic materials like WC are also very stable due to their higher melting point. In terms of offering a shield to bearings, the Tungsten Carbide Coating can be very powerful and useful.  

Benefits Tungsten Carbide Carbon Coating Offers to Bearings

There are many benefits that tungsten carbide carbon coating offers to bearings. This coating is extremely hard and wear-resistant, making it ideal for applications where bearings are subject to high levels of wear and tear. The coating also has excellent corrosion resistance properties, making it ideal for use in harsh environments. Additionally, the coating is very smooth, providing low friction and excellent sliding properties.

Use Of Bearings in the Automobile Industry

  Bearings are one of the crucial components which are used in automobile parts. From steering and transmission to wheels, the bearing is useful to support the operations at varying levels. Read this blog to know more about the Use of Bearings in the Automobile Industry. The automobile industry is one of the largest industries that source bearings in huge numbers. As every part of machinery within a car, truck or bus requires bearings to support operations and function heavy duty parts, bearings are something that can’t be missed. The axle, engine, motors, and steering are some of the integral parts that have bearings at a large scale to make them work to make them operate smoothly while reducing friction. As the need for new makes and models are surging, the requirements for manufacturing bearings for automobiles are also soaring up high. With the latest trends and innovations, the bearing manufacturers are also revving up their bearing design to accommodate new-age solutions.

Use of Bearings in the Automobile Industry

As you may already know it is next to impossible for automobile parts to function without the use of bearings. Here are various points that can help you know why bearings are crucial for automobiles.

1. Bearings Help in “Reducing Friction”

The main objective of using bearings is to reduce the friction between contact points. As metal to metal contact can give rise to issues such as wear and tear or breakdown, the bearings make it possible for various parts to function altogether while ensuring a proper contact and loadbearing capacity.

2. Bearings Help in Guiding Movement of Automobile Parts

Bearings are used for the purpose to move and turning the components of automobile parts relatively in a certain direction. It can support and guide the parts such as the wheel or steering shaft to offer ease of movement without any complexity. That is exactly how it makes it possible for steering to move the wheel in the desired direction.

3. Bearings Support Load Bearing Capacity

The bearings are made in such a way that they can easily bear thrust, angular and radial loads. Due to the design and manufacturing, the bearings are heavy-duty components that have the capacity to bear the maximum load as per various applications which may change from part to part. The type of bearing used here can also differ in such cases.

Major Automobile Parts that use Bearings

Here are various automobile parts that use different types of bearing to support the smooth functioning and operation of the vehicle: Transmission The transmission is the most crucial device which converts the energy from the engine to adapt to the driving speed through gears. In such cases, the bearings are used to support the shaft to apply the desired force which controls the speed. The deep groove ball bearing, cylindrical roller bearing and tapered roller bearing can be used in such applications as per different axial and radial loads Wheels The Ball Bearings can be used on wheels to support mobility. The bearings are fitted in the “cage” through which they evenly distribute the load of the vehicle. It also ensures the proper functioning of tire, wheel and hub assemblies. Engine The piston engine in automobiles uses various bearings to support the crankshaft and rotation of parts within the engine during the operation. In such cases, different types of bearings such as tapered roller bearing, ball bearing, ball thrust bearings, etc are used.   Conclusion The bearings come with exceptional capabilities to support varied operations within machinery. From handling load to working for longer hours without failure, bearings are crucial components that makeup machinery or systems. Since the automobile sector is growing and changing rapidly, the need to modify bearing design and performance have become more prevalent than in the past for bearing manufacturers.

Bearing Maintenance Training & Tips From The Industry Experts

The bearing maintenance can help in ensuring the long service life which results in optimum performance and prevention from failure. This blog covers various tips from industry experts that can help you do the maintenance of bearing in the right way.
Bearings can be considered an important part of the machinery. If you have ever tried to repair a machine that was not working properly due to worn-out bearings then you know how expensive it is. A broken bearing will always cost more than its replacement, so it is always better to prevent the need for replacements in the first place. This article gives some tips on bearing maintenance training and tips from the Industry Experts.
Why Take Care of Bearing Maintenance
The bearings do carry a huge load and these are small parts that ensure operations within a huge machine. The failure of bearing can become a problematic issue that will result in machine downtime and loss of optimum efficiency. The breakdown of bearings can also cause serious machine or equipment failure.
Bearing Maintenance Training & Tips from The Industry Experts
  1. Inspect Your Bearings Regularly:
    It is essential to inspect your bearings regularly. You must check them at least once every month. Make sure they are clean and free of any debris. If there is dirt or grease around the outer ring, then you should remove it with a rag. You should also make sure that the inner ring is smooth and has no rough spots. If you notice any damage to either the inner or outer ring, then you may need to replace them.

  2. Check All Bearings For Cracks And Leaks:
    When you take apart your machine, check all the bearings. Look at each one carefully, if you see any cracking or leaking, stop using the bearing until you replace it. Don’t just assume that your bearings are fine, even if they seem to be okay.
  3. Check for Loose Parts:
    If you find any loose parts such as nuts, bolts, etc., then you should tighten them up before you start using the equipment. If you don’t do this, then these parts could fall off and cause serious problems.

  4. Grease Replacement:
    If you notice that your bearings are dry, it means that the grease has been completely removed from the bearing. This may indicate that the bearing is damaged. In such cases, you should replace the bearing immediately.

  5. Keep Your Bearings Clean:
    Always keep your bearings clean by removing dirt particles. Use a brush or a vacuum cleaner to remove any dust particles which may get stuck between the races. Make sure to use only a soft bristle brush when cleaning your bearings. Never use metal brushes as they can damage the surface of the bearing.

  6. Inspect the Inner Ring of Your Bearing: When inspecting the inner ring of your bearing, look for signs of damage. Excessive wear or damage to the inner ring of the bearing could cause the outer race to become loose or even start spinning freely. In such cases, it would be best to replace the entire bearing assembly.

  7. Replace Old Bearings with New Ones:
    The bearings are prone to wear out over time. If your bearing has been used for a long time, chances are it needs replacing.

  8. Prevent Bearings from Corrosion:
    The corrosion can impact longevity in the life of bearings as it impacts the operational efficiency and may also result in machinery breakdown. The only solution to tackle this is to use genuine stainless-steel bearings that can withstand corrosion.
  9. Monitoring Bearing Performance:
    The excessive noise or vibration in the bearing can be a sign of a serious problem that can lead to bearing damage.

  10. Align Machine in Right Way:
    The assembling misalignment can be another reason which can cause failure or breakdown of bearing. The right advice is to always check for proper housing and assembling of bearings to prevent such failures.
The bearing maintenance is an integral thing to ensure that bearings don’t break down before the specified time or life. Since replacement of bearings can cost huge, it becomes important to keep a track of maintenance in the right manner. It is always advisable to follow recommended practices of maintenance to ensure the bearing works right in the optimum way

Common Causes of Bearing Failure and How to Avoid Them

Bearings are a crucial part of machinery and failure can cause a significant impact on the overall functioning of machinery. In order to help you ensure the proper functioning of bearing, this blog discusses various aspects of common causes of bearing failure and ways to avoid them.

The bearings offer a lifeline to various equipment and machinery across a wide range of industrial sectors. From a two-wheeler to an aero plane, bearings are used everywhere to support machinery and its operations. They are the small pieces of big machinery that handles load and weight while powering mechanical systems to ensure smooth operations. While every piece of equipment comes with the specified life, this same applies to bearings as well. It depends on multiple conditions on how a bearing fails as it may not be just limited to usual conditions like- wear and tear or corrosion. This blog discusses various causes of bearing failure and tips on how you can avoid it.

Bearing Failure Can Cause Machinery to Break Down

The lack of maintenance of the bearing can result in machinery breakdown which can further impact the functioning of the overall system. This doesn’t only cause an effect on bearing but can also damage machinery in varied ways.

Common Causes of Bearing Failure & Solutions

The Bearings also do come with service life and there are varied reasons why a bearing can fail.

Here are the different causes of bearing failure and its solutions:

  • Lubrication: The lubrication needs to be applied in a balanced way. If machinery or bearings have been applied with improper lubrication such that- over greasing, under greasing, etc. It may cause various problems and break down the bearing. The only solution to tackle this is to use lubrication in moderation and also ensure the type of grease quality used in it.

  • Working Conditions of Bearings: It is also taken into consideration which environment the bearing is exposed to. If it is exposed to water, dust, sand, etc. it can lead to corrosion or erosion of the bearing surface leading to premature failure. In order to protect bearings from such conditions, it is always recommended to check the usage conditions and suitable conditions where bearings can work efficiently.

  • Bearing Fatigue: The overhauling of the bearing can lead to its failure which can happen due to over-utilization. In such conditions, it fractures the surface of bearings and results in breakdown. The solution to ensure bearing fatigue is to perform scheduled maintenance on a regular basis so as to check for the scope of replacement.

  • Misalignment and Shifting of Bearings: The bearings are very small pieces that are attached to machinery or equipment to make them work. There are possibilities that due to overuse or various other conditions, the bearing can get misaligned from its ideal position making it break down.

  • Installation Errors: Installation errors are quite common as they may lead the bearing to get damaged before its service life. It is always important to ensure and verify that the right kinds of tools are used to install the bearings.

Avoiding Bearing Failures

Bearing Failures can incur costs in varied ways as they can also affect the operational efficiency of machinery and equipment. The best way to avoid bearing failures is to perform regular maintenance, do regular greasing or lubrication based on bearing manufacturer guidelines, and check for any faults or misbehavior. Another aspect to ensure bearing failure doesn’t happen is to install bearings properly with the right kind of tools while taking care of proper fixation and alignment. The bearing maintenance should be a primitive part of the process which helps you save the cost of repairing or replacing the bearing by performing preventive maintenance.

Running Diagnostic Tests to Ensure Smooth Operations

There are various ways through which you can perform predictive checks to ensure that bearings are working as per their defined efficiency. Diagnostic Tests like Root Cause Failure analysis can track any potential failures or wear/tear conditions to ensure that the bearings are in proper shape. Apart from it, IR-based thermography can also be run to conclude temperature-related conditions. These tests are crucial to ensure that the bearings don’t run out before the time.


A Leap forward in Environmental Sustainability

Environmental Sustainability Above and Beyond

The environmental agenda, one of the major pillars of sustainable development, often intersects with multilateral trade obligations. Amidst the echoes of environment, climate change, and sustainable development worldwide, NEI has gone above and beyond boundaries to implement sustainability measures with a view to reducing carbon footprint.

Recently having obtained the Green Factory Building Platinum Certification by the Indian Green Building Council (IGBC) for having maintained efficiency of energy consumption and water usage that has been effective in sustaining a village of 300 houses for two consecutive months, plus the ISO 50001 approval for our Jaipur plant as a global recognition for our Energy Management System, we are gearing towards reaching out to more global customers who are looking to partner with an energy-efficient and sustainable enterprise. Our plant in Savli, Vadodara is also IGBC platinum-certified, adopting all green manufacturing practices right from the start.

Environmental Sustainability – Larger Perspective in Practice

Our larger objective lies in reducing energy consumption and improving energy efficiency to support our overarching goal of lowering GHG emissions and Carbon Footprint. In other words, leveraging opportunities to spur the transfer and dissemination of environment-friendly and clean-energy technology as a leading exporter and manufacturer of bearings is what we constantly aim for.

We have been undeterred in extending our endeavor further in our sustainability mission—ranging from implementing all best-in-class practices with supreme standards of water and energy conservation, waste management, and reduction in CO2 emission, to maintaining environmental quality.

NEI’s rainwater harvesting exercise has ensured saving more than 6 million liters of water annually. In addition, wastewater released from the factory is treated on-site in the Effluent Treatment Plant (ETP) and Sewage Treatment Plant (STP). This is in turn used for landscaping the campus areas, consequently resulting in zero discharge outside of the plant. We have reduced water consumption in our Jaipur Plant by 40% in the last five years. In fact, we have a six-sigma project running currently for the reduction of water consumption at the factory site.

The facility in Rajasthan, with its sustainable green building design, also optimizes natural daylight and uses effective lighting and air-conditioning systems to reduce its energy consumption by 39 percent. With its 1500 KW rooftop solar and 100 percent LED lighting, the facility contributes by further decreasing its carbon footprint to 38 percent.

In addition, we have also partnered with our customers for participation in their Carbon disclosure project (CDP), as they strive toward bringing about environmental improvements in their supply chains. However, it doesn’t end there. To maintain environmental quality further, we have also begun to use returnable packaging solutions that help in the reduction of packaging waste.

Our GHG Emission Metrics

To calculate the Green House Gas emissions inventory, we collected activity data from the various locations we identified as sources of GHG emissions. We then applied the emission factors and subsequently derived data on emissions from each source.

We further aggregated this to the corporate level for calculating NEI’s total Carbon footprint. As per the data analyzed for immediate bearing manufacturing competitors for Carbon emission from all 94 manufacturing units around the globe, the emission is around 1.225 M tonnes of the net equivalent. On the contrary, NEI has around 0.105 M tonnes of net equivalent Carbon emission from its 5 manufacturing units.

Towards a Greener Future

While we discuss aspects of environmental sustainability, we cannot play on the back foot when it comes to acknowledging aspects of economic and social sustainability. Sustainable development from a holistic point of view would be achieved only when there is either a balance or a trade-off between these three aspects. NEI takes pride in being part of this mission and will continue playing its part to its maximum potential.