When you’re managing industrial machinery, from turbines and motors to pumps, the last thing you want is a worn bearing grinding your operations to a halt. Bearings might seem like a minor component, but they play a critical role in keeping equipment running smoothly. The problem? Bearings wear down over time. The solution? Arc flame spray—a cutting-edge repair technique that’s transforming the way industries tackle bearing maintenance in 2024.

At Fusion Babbitting Co., located in Milwaukee, WI, we’ve been perfecting this technology to help industries reduce downtime and save money. In this blog, we’ll break down what arc flame spray is, why it’s such a game-changer for bearing repair, and how it’s shaping industrial operations in 2024.

To put it simply, arc flame spray is a thermal spraying process that restores worn surfaces on metal components, such as bearings. The process involves melting metal wire into droplets and spraying them at high speed onto a surface. These droplets build up to form a new, durable layer that can withstand wear, corrosion, and high temperatures. Essentially, it’s like giving your old bearings a second life—and sometimes making them even better than before.

In 2024, this repair technique is gaining momentum as industries increasingly focus on sustainability, cost-efficiency, and keeping operations running smoothly amid ongoing supply chain delays. Rather than replacing a worn bearing with a new one—which can be expensive and time-consuming—companies are turning to arc flame spray to restore their existing parts.

Let’s face it: Downtime in industrial settings is costly. Every minute your machinery isn’t operating at full capacity is a minute of lost revenue, delayed projects, and mounting frustration. With the ongoing supply chain challenges of 2024, waiting for replacement parts is less than ideal. That’s where arc flame spray comes in as a faster, more reliable solution.

At Fusion Babbitting Co., we use arc flame spray to quickly restore bearings, saving our clients both time and money. But what makes this process a true game-changer is its ability to create a new, wear-resistant surface that extends the life of your bearing. In fact, many of our customers have found that bearings restored with arc flame spray last even longer than new ones.

In industries like hydropower, nuclear energy, and pumping systems, where downtime isn’t just a nuisance but a major financial setback, the ability to repair bearings in a matter of hours or days instead of weeks is invaluable. And for industries that depend on precision and safety, arc flame spray offers a reliable solution that meets and often exceeds OEM (Original Equipment Manufacturer) standards.

Here at Fusion Babbitting Co., we’ve been helping industries across the U.S. with high-quality bearing repair and custom manufacturing for years. Based in Milwaukee, we take pride in providing specialized services such as rebabbitting, reverse engineering, fabrication, and machining of bearings. But what really sets us apart is our mastery of arc flame spray technology.

Our expert team has fine-tuned the arc flame spray process to deliver precise, custom repairs for a variety of industries. Whether you’re running motors, turbines, pumps, or other heavy machinery, we’ve got the skills and technology to get your equipment back in top shape. In 2024, when industrial efficiency and reliability are more important than ever, Fusion Babbitting is the name you can trust for long-lasting bearing repairs.

Still wondering why so many companies are choosing arc flame spray over traditional methods? Let’s break it down.

• Reduced Downtime: Time is money in the industrial world. With arc flame spray, you don’t need to wait for new parts to arrive. Fusion Babbitting can often repair your bearings in Milwaukee in just a fraction of the time it would take to order a replacement.
• Cost Savings: Not only does arc flame spray minimize downtime, but it’s also far more cost-effective than replacing bearings. This is especially true in 2024, where rising material costs and supply chain delays make new parts more expensive and harder to come by.
• Prolonged Bearing Life: Bearings repaired with arc flame spray are often more durable than new ones, thanks to the high-quality materials used in the process. In some cases, our customers have reported that their repaired bearings lasted longer than they initially expected.
• Environmental Impact: By restoring existing parts instead of manufacturing new ones, arc flame spray reduces waste, making it a more sustainable option in 2024.

Precision matters in industrial operations. A poorly repaired bearing can lead to further wear and tear on your machinery, causing additional downtime and potentially damaging other components. That’s why, at Fusion Babbitting Co., we ensure that every bearing we repair with arc flame spray meets or exceeds OEM specifications.

Our team of experts uses state-of-the-art equipment to perform repairs with exacting precision. This attention to detail is particularly important for industries like nuclear energy and hydroelectric plants, where even the smallest error can lead to major problems. With Fusion Babbitting, you can rest assured that your equipment is in safe hands.

Arc flame spray isn’t just for theory—it’s being put to work in real-world applications across a wide range of industries. In Milwaukee and beyond, we’ve seen firsthand how this technology is transforming the way companies approach bearing repairs.

For example, hydropower plants rely heavily on turbines that operate under extreme conditions. Bearings in these turbines are constantly exposed to high temperatures, pressure, and wear. Rather than replacing these bearings every few years, companies are turning to arc flame spray to restore them, significantly extending their lifespan and reducing overall maintenance costs.

Another example comes from desalination plants, which use large pumps to process seawater. These pumps operate 24/7 and are crucial to the plant’s efficiency. By using arc flame spray, these facilities can restore worn bearings in their pumps quickly and effectively, ensuring continuous operation without the need for expensive replacements.

Bullet Points: The Key Benefits of Arc Flame Spray for Bearings

• Cost-Effective Repairs: Save money by repairing instead of replacing.
• Quick Turnaround: Reduced downtime means your equipment is back in action faster.
• Extended Lifespan: Bearings repaired with arc flame spray often last longer than new ones.
• OEM-Level Precision: Repairs meet or exceed original manufacturer standards.
• Sustainable Solution: Reduce waste by restoring existing parts instead of manufacturing new ones.

Looking to avoid costly downtime and keep your machinery running smoothly in 2024? Fusion Babbitting Co. is here to help. Our team of experts specializes in arc flame spray repairs that extend the life of your bearings, saving you time and money. We work with a variety of industries, from pumping systems to hydroelectric plants, offering custom solutions that are tailored to your specific needs.

By choosing Fusion Babbitting, you’re not just getting a quick fix—you’re getting a partner dedicated to helping your business thrive. Our services go beyond repairs; we offer proactive maintenance plans to ensure your equipment stays in top condition all year long.

In 2024, a proactive approach to machinery maintenance is essential. Rather than waiting for bearings to fail, it’s better to catch wear early and restore the bearings before a breakdown occurs. This not only keeps your equipment running smoothly but also prevents costly emergency repairs.

Fusion Babbitting Co. offers routine inspections and maintenance plans tailored to your needs. Our team will work with you to identify any potential issues and address them with arc flame spray before they become major problems. With our help, you can avoid unexpected downtime and keep your operations running efficiently.

Don’t Let Worn Bearings Slow You Down in 2024

If your bearings are showing signs of wear, don’t wait for them to fail. Contact Fusion Babbitting Co. in Milwaukee, WI, today to learn how arc flame spray can save you time and money. Our expert team is ready to provide fast, reliable repairs that extend the life of your machinery and keep your operations running smoothly. Reach out now to schedule a consultation or repair, and stay ahead of the game in 2024.