Current Industrial Challenges of BearingsThere are several industrial challenges that frequently occur in various applications and the bearings should be able to take the heat for the finest performance. Here are some of the current industrial challenges of bearings:
- Paper industry (calender machine): It has a very wide load range and zero load situations. It can create problems such as sliding, smearing damage, and micro-welding.
- Hydraulic application (pumps and motors): The motors and pumps may have varied challenges such as low viscosity lubrication which can result in conditions like wear-tear and friction. Without the proper coatings on bearings, the durability also diminishes.
- Power plant (coal pulverizer): Coal pulverizers in power plants may face challenges due to contamination and vibration with low-viscosity lubrication. In different levels of production where coal is required, problems like abrasions, micro pitting, smearing, etc. can happen under these circumstances.
Solution – Tungsten carbide carbon coating in BearingsThe challenges of bearings in a high-performing environment in the paper industry, hydraulic applications, power plants, etc. can be resolved using the tungsten carbide carbon coating to prevent wear and tear, abrasions, smearing, etc. Here are some of its features that make it ideal for the use of coating bearings:
- Increased resistance to wear and tear – The coating can help to protect the bearings from wear and tear, which can extend their lifespan.
- Reduced friction – The coating can help to reduce friction between the bearings and the surrounding components, which can improve performance.
- Protection against corrosion – The coating can help to protect the bearings from corrosion, which can also help to extend their lifespan.
Characteristics of Tungsten Carbide Coatings in BearingsHere are some of the characteristics of tungsten carbide coatings in bearings:
- Very thin coating: it has a very thin coating of 1-2 um. It helps in low friction and has great sliding properties. Even with the thin coating, its high melting point resists wearing effectively.
- High adhesion strength (HF1 to HF2 grade): Tungsten carbide coatings applied with high-velocity oxygen fuel (HVOF) lead to stronger adhesion, corrosion resistance, and low porosity, which helps the bearings work very smoothly.
- High hardness (1000-1500 HV): When tungsten carbide coating and detonation gun (d-gun) are applied together, there is a strong bond created, resulting in hardness, no wear-tear, and protection from erosion, which makes bearings more durable.
- Lubrication: Hard coating on rolling elements polishes the race’s surface and the carbon layer provides lubrication for the traction-improving devices. This is the reason it is used in horseshoeing. Carbon-tipped hoof nails are also used to mount the shoes.
- Increased Life for Bearing: In thin oil or contaminated oil condition, the bearing life can be increased 3x as compared to the normal bearing.