Bearing damage in industrial machinery can bring operations to a grinding halt, leading to costly downtime, unexpected repairs, and even equipment failure. When issues arise, business owners are faced with a crucial decision—should they rebuild the bearings or replace them entirely? Choosing the right option can not only save money but also improve equipment longevity and performance. Fusion Babbitting, an industry leader in bearing services, helps businesses navigate this decision using over 40 years of combined experience.

Lack of Lubrication

One of the most common causes of bearing damage is insufficient or contaminated lubrication. Lubrication minimizes friction and wear, but when it breaks down, the results can be devastating. The bearing surfaces heat up, leading to scoring, pitting, or even seizing.

Vibration and Misalignment

Industrial machinery operates under continuous stress. If shafts are misaligned or if excessive vibration occurs due to structural problems or environmental factors, bearing wear escalates quickly. Misalignment can also cause uneven loading, accelerating damage.

Contamination

Dust, dirt, and other particulates can infiltrate bearing enclosures, especially in industries like mining, cement plants, or paper mills. Once inside, these contaminants compromise the material integrity, causing premature failure.

Overloading and Improper Handling

Exceeding a bearing’s design load or improper installation can shorten its lifespan significantly. Even small mistakes like using incorrect tools or mishandling the component can lead to avoidable damage.

When Rebuilding Bearings Makes Sense

Rebuilding industrial bearings is often the most cost-effective solution, especially when the core structure is still intact. Fusion Babbitting specializes in high-quality rebuilding services that restore bearings to OEM specifications or better. Here’s when rebuilding is smart:

– The bearing shell or housing is in good condition – Damage is limited to the Babbitt lining or surface wear – Custom or obsolete parts are difficult or expensive to replace – The original bearing was high-quality and worth restoring

Rebuilding can cost significantly less than manufacturing or ordering a replacement, especially for large or custom parts used in turbines, pumps, or electric motors. Fusion Babbitting offers centrifugal casting and arc flame spray applications, which not only restore but enhance the original part’s durability and performance.

When Replacing Bearings Is Necessary

In some cases, complete replacement is unavoidable. Fusion Babbitting also provides custom high-precision bearing manufacturing when rebuilding isn’t a viable option. Your choice to replace may be driven by:

– Severe or widespread structural stress fractures – Corrosion beyond recovery – Modern upgrades requiring new components – Short timelines where rebuilding would take too long

Fusion Babbitting’s new manufacturing service ensures your equipment receives a fresh start with premium-quality bearings that meet and exceed OEM requirements. For highly worn or non-repairable parts, replacement ensures longer service life and reduced risk of recurring damage.

Rebuilding offers many benefits for industries relying on specialized or oversized bearings. Fusion Babbitting’s skilled team uses advanced machining techniques and certified materials for rebuilding, ensuring long-term success.

Cost Savings

Bearings can be expensive, especially in hydro power systems or marine applications where custom specs are required. Rebuilding a damaged bearing can save anywhere from 30% to 70% compared to buying new.

Shorter Lead Time

Ordering new bearings often means waiting for months, particularly for obsolete or unconventional sizes. Rebuilding an existing bearing is usually faster. At Fusion Babbitting, 24-hour emergency rebuild services help you minimize downtime and resume operations quickly.

Eco-Friendly Option

Rebuilding reduces material waste by utilizing existing structures. It’s a more sustainable solution, aligning with environmental initiatives across industries like steel mills and paper production.

Maintains Original Specifications

Fusion Babbitting uses precision machining and certified Babbitt materials to rebuild bearings while maintaining the original geometry. This makes sure the rebuilt bearing performs just as well—or better—than the original.

Since 1988, Fusion Babbitting has served industries nationwide from its facility in Milwaukee, WI. They offer a full range of bearing solutions, including reverse engineering, fabrication, machining, and customized bearing builds. Their specialized services are trusted across industries including:

– Aluminum Mills – Fossil & Nuclear Plants – Cement & Chemical Plants – Mines & Steel Mills – Hydro/Pump Storage – Marine Repair – Shipyards

Fusion Babbitting stands out by providing:

– Around-the-clock emergency services – Certified centrifugal casting processes – Arc flame spray reclamation – Custom fabrication up to 120 inches in diameter

With their reverse engineering service, Fusion Babbitting replicates obsolete or missing bearing parts using detailed drawings and measurements. This is particularly valuable when original components are no longer available from OEMs.

High-Precision Babbitting Techniques

Fusion Babbitting uses advanced ball and journal bearing technologies, including hand and centrifugal casting with multiple Babbitt alloy options like tin-based and lead-based compositions. Every rebabbitted bearing undergoes ultrasonic bond testing to ensure maximum bond strength and longer service life. Their technology guarantees bearings perform exactly as intended under demanding industrial loads.

Fusion Babbitting’s Dedication to Quality

Their commitment to quality is reflected in their ASME-qualified welders and a highly skilled team of machine operators and engineers. With over three decades of experience and continuous training, Fusion Babbitting ensures each project meets strict quality control benchmarks using precision inspection tools including laser alignment and coordinate measuring machines (CMM).

Evaluate Bearing Condition

Start by assessing the extent of your bearing damage. Small cracks, worn metal, or lining failure often point toward rebuilding. A Fusion Babbitting technician can inspect your part and provide a detailed evaluation to guide your decision.

Compare Long-Term Value

While replacement may have higher upfront costs, it could provide longer service life. Rebuilding is typically cheaper and faster but may require more frequent maintenance depending on the severity of prior damage.

Consider Application Demands

Critical systems like turbines or hydro power plants may benefit from new parts designed with modern materials and technology. On the other hand, older machinery or rarely used components are prime candidates for rebuilding.

Consulting with Fusion Babbitting ensures the decision you make aligns with your equipment’s needs, your budget, and your operating timelines.

– Is the bearing structure still intact? – Can the damage be repaired without weakening performance? – Is rebuild time faster than ordering and receiving a replacement? – Are OEM parts still available or obsolete? – How critical is the application this bearing serves?

Whether you’re facing minor bearing damage or major failure, Fusion Babbitting provides expert insight to help you make the most cost-effective, reliable choice. Their advanced equipment, combined with decades of experience, ensures every bearing—whether rebuilt or replaced—meets the highest standards of quality.

By partnering with Fusion Babbitting, industries across the United States are seeing improved reliability, reduced downtime, and better long-term cost savings on their equipment. Whether it’s electric motors, turbines, hydro systems, or pumps, they have the knowledge and capability to support your operations with dependable bearing solutions.

To speak with an expert or request a quote, contact Fusion Babbitting today:

Address: 4540 W. Burnham St., Milwaukee, WI 53219 – Phone: 414.645.5800 | Toll-Free: 800.613.5118 – Email: sales@fusionbabbitting.com

Bearing damage doesn’t always lead to replacement. Often, rebuilding is the smarter, more economical choice—especially when done by a trusted provider like Fusion Babbitting. From quick turnaround repairs to custom-manufactured units, they offer flexible options based on your operational and budget needs. Make the smart decision today by working with proven experts who care about your success.