Fusion Babbitting designs and manufactures precision bearing shells and liners for engines and heavy rotating machinery. If you need a new bearing set made to exact size, matched to your housing, and finished to a tight tolerance, our team delivers. Since 1988, Fusion Babbitting Co., Inc. in Milwaukee, WI has supported plants, shipyards, utilities, and repair shops across the United States with new manufacture, rebabbitting, and rebuild services. We offer rapid turnaround, certified Babbitt materials, and 24 hour emergency support to keep your equipment running safely and efficiently.
What Are Bearing Shells and Liners
Bearing shells and liners are critical wear components that support a rotating shaft on a thin film of oil. In engines, motors, pumps, and turbines, these parts create a stable hydrodynamic surface that reduces friction and heat. Shells are often split into two halves that fit into a housing bore. Liners describe the Babbitt layer or insert that provides a soft, conformable running surface against the shaft. Together, the shell and liner control clearance, alignment, and oil film stability. When manufactured and installed correctly, they protect the shaft, extend equipment life, and improve reliability.
Fusion Babbitting produces new bearing shells and liners for many types of equipment, including journal and thrust configurations, split or solid designs, and special geometries with oil grooves, lubrication ports, and reliefs. Whether you need a one off for a legacy machine or a production run for an OEM program, our new manufacture process is built to deliver consistency and accuracy.
Why Choose New Manufacture from Fusion Babbitting
There are times when repair or rebabbitting is the right choice, and there are times when a brand new bearing is the safest and fastest solution. Fusion Babbitting helps you evaluate both paths. When you select new manufacture, you get a clean start with geometry, materials, and clearances optimized for your current operating conditions.
- Severe damage or wear has compromised the base metal of the original shell
- OEM drawings are unavailable and you need a custom engineered replacement
- You want upgraded Babbitt materials or improved oil groove design
- Lead time for a factory part is too long and downtime is costly
- Dimensional changes are required to match a repaired housing or shaft
Fusion Babbitting specializes in fast, precise new manufacture of bearing shells liners. We help you minimize downtime with a streamlined quoting process, realistic lead times, and 24 hour emergency support when the situation demands it.
Materials and Manufacturing Methods We Use
Certified Babbitt Alloys
Babbitt is a family of soft, conformable alloys chosen for their excellent embedability, fatigue resistance, and low friction. At Fusion Babbitting, we pour certified Babbitt materials selected for your speed, load, and temperature profile. Our team helps you choose the proper alloy thickness and bond to support your application, from high speed electric motors to large turbine journals and engine main bearings.
Centrifugal Casting for Strong Bonds
Centrifugal casting produces a dense, uniform Babbitt lining with strong bond strength to the base metal. The spinning action forces impurities outward and promotes a consistent metallurgical connection, reducing porosity and improving bearing integrity. Fusion Babbitting has refined this process to deliver repeatable results across small and large shells, so your new bearing arrives with the structure and thickness you expect.
Precision Machining and Finishing
After casting, our machinists finish the bearing to exact size and geometry. We hold tight tolerances on inside diameter, length, and wall thickness. Oil grooves, chamfers, parting line reliefs, and radii are machined to your drawing or to proven Fusion standards when prints are not available. We verify crush and spread for split shells, and we machine housing fits for proper seating. The result is a bearing that locks in place, carries the load, and promotes stable oil film formation.
Arc Flame Spray for Mating Components
Many new builds involve mating parts that need attention. We use arc flame spray to restore worn components, then machine them back to nominal dimensions. When a housing bore is oversize or a cap has lost crush, this process allows us to recover the fit and ensure your new bearing shells liners perform as intended. The goal is a matched set: shell, housing, and shaft all working together.
Our New Manufacture Process for Bearing Shells Liners
We designed our workflow to deliver accuracy, speed, and transparency. From quote to shipment, you will know where your job stands and what to expect.
- Application review and quoting: We discuss your machine, operating conditions, and deadline. You share a drawing, sample, or critical dimensions. We provide a clear quote and lead time.
- Reverse engineering or drawing confirmation: If prints are not available, Fusion Babbitting inspects your sample and creates detailed drawings that capture critical features such as clearances, groove patterns, and parting line geometry.
- Material selection: We select certified Babbitt alloy and base materials suited to load, speed, and temperature. We confirm thickness and structure for your liner.
- Centrifugal casting: We cast the Babbitt lining to achieve strong bond strength and consistent thickness.
- Rough and finish machining: We machine the outside diameter and inside diameter, oil features, reliefs, and seating surfaces to exact size.
- Inspection and quality control: Dimensions, clearances, and finish are verified against your requirements. Bond integrity and alignment are checked.
- Trial fit and documentation: For complex projects, we perform trial fits in shop fixtures. We finalize drawings and notes for your records.
- Packing and shipping: Bearings are protected with rust inhibitors, packed to prevent damage, and shipped to your site. Expedited shipping is available.
Quality Assurance and Testing
Quality is built into every stage. Fusion Babbitting uses certified Babbitt materials, controlled casting practices, and calibrated inspection tools. We verify dimensions, surface finish, and parting line condition. We check crush and spread on split shells and confirm seating fits. Where specified, we perform bond checks and provide inspection reports. Our goal is to deliver bearing shells liners that install cleanly and run free on the first start.
Engine, Motor, and Turbine Applications
Fusion Babbitting manufactures bearing shells and liners for many machines. From diesel and gas engines to hydro turbines and mill motors, our team understands the demands of each system. Clearances, grooves, and materials are matched to your oil type, speed, and load. For engines, we build main and connecting rod shells with precise oil holes and crush for secure seating. For motors and pumps, we produce journal bearings with smooth finishes that support stable hydrodynamic films. For turbines, we machine large shells with controlled geometry for thermal stability.
- Electric motors and generators
- Hydro power and pump storage systems
- Industrial pumps and gearboxes
- Steam and gas turbines
- Diesel and gas engine mains and rods
Industries We Serve Nationwide
Located at 4540 W. Burnham St., Milwaukee, WI, Fusion Babbitting supports facilities across the country. Our new manufacture of bearing shells liners helps critical machinery run smoothly in demanding environments.
- Aluminum mills
- Cement and chemical plants
- Fossil and nuclear plants
- Hydro and pump storage
- Marine repair and shipyards
- Mines and steel mills
- Motor repair shops
- Paper mills
- Crushed stone producers
Capabilities and Size Range
Fusion Babbitting handles components up to 120 inches in diameter and length. We have the equipment, tooling, and experience to work on small engine shells and large turbine bearings. Whether you need a single set or a batch for an OEM program, our process scales to your needs. We also support general fabrication and machining, which helps when housings and mating parts require attention to achieve proper fits.
Reverse Engineering of Obsolete Bearings
When OEM parts are no longer available, Fusion Babbitting reverse engineers your bearing shells and liners. We document dimensions, oil features, and critical alignments, then build a clean drawing that becomes the basis for new manufacture. If you want to improve performance, we can suggest changes to groove patterns or materials based on your operating data. With detailed drawings and clear labeling, your team has a repeatable specification for future replacements.
Repair vs Rebabbitting vs New Manufacture
Choosing the right service saves time and money. Repair may be best when only light scoring is present and base metal is intact. Rebabbitting is ideal when the shell is structurally sound, but the lining is worn or damaged. New manufacture is often the safest choice when the base shell is cracked, distorted, or missing, or when you need a different size to match a repaired housing or shaft. Fusion Babbitting offers all three approaches. We help you decide with a practical assessment focused on reliability and lead time.
Installation Support and Best Practices
Proper installation is as important as precise manufacturing. We recommend clean, burr free housings and shafts, careful measurement of crush for split shells, and confirmation of oil clearance. Check alignment, oil supply, and filtration. After installation, follow a controlled run in procedure. Monitor temperature and vibration. Fusion Babbitting can advise on best practices and provide guidance based on your equipment and operating environment.
Fast Turnaround and Shipping
Downtime is expensive. Fusion Babbitting commits to realistic schedules and proactive communication. We offer rush support and 24 hour emergency service when needed. Your bearings ship in protective packaging with rust inhibitors and clear labeling. We arrange nationwide shipping and can coordinate with your maintenance window to help you return to service quickly.
How to Request a Quote
Getting a quote for new bearing shells liners is simple. Share the equipment type, dimensions, material preferences, operating speeds, loads, and temperature range. A drawing or sample helps us move faster. Photos of the housing and shaft are useful when prints are not available. Email sales@fusionbabbitting.com or call 414.645.5800. Toll free at 800.613.5118. You can also visit us at 4540 W. Burnham St., Milwaukee, WI 53219. We respond quickly with pricing, lead time, and any questions we need to confirm.
FAQs About Bearing Shells Liners
Can you match or improve OEM designs
Yes. Fusion Babbitting can build to OEM drawings or replicate a sample. If you want to improve performance, we can review oil grooves, reliefs, and clearances based on your operating conditions. Many clients see longer life with small changes that improve lubrication and heat transfer.
What tolerances can you hold
We machine to tight tolerances on inside diameter, wall thickness, length, and geometry. Final tolerances depend on size and design. Share your requirements and we will confirm our capability for your specific bearing.
What is the typical lead time
Lead time depends on size, complexity, and current workload. Standard orders often ship in days to weeks. We offer rush service and 24 hour emergency options for critical outages. Contact Fusion Babbitting for a schedule tailored to your needs.
Do you provide documentation
Yes. We provide drawings for reverse engineered parts and inspection records when specified. We also keep internal documentation for repeatability on future orders. This supports consistent quality and shorter lead times next time you order.
Can you handle large bearings
Yes. Our facility supports components up to 120 inches in diameter and length. We regularly manufacture and machine large shells for turbines, hydro units, and mill motors.
Do you ship nationwide
Yes. Fusion Babbitting serves clients across the United States. We package carefully to protect surfaces, and we coordinate carriers to meet your maintenance schedule.
About Fusion Babbitting
Fusion Babbitting Co., Inc. has focused on precision bearing solutions since 1988. Based in Milwaukee, WI, our team brings more than 40 years of combined expertise to every project. We specialize in Babbitt bearing repair, rebabbitting, rebuilding, reverse engineering, and new manufacture. We support a wide range of industries, including aluminum mills, cement and chemical plants, fossil and nuclear power, hydro and pump storage, marine repair, mines and steel mills, motor repair shops, paper mills, shipyards, and crushed stone producers. Our commitment is simple. We deliver bearing shells and liners that improve reliability and reduce downtime. From centrifugal casting to final inspection, every step is controlled so your equipment runs as intended.
Get Reliable Bearing Shells Liners Today
If you need new manufacture bearing shells liners for engines, motors, pumps, or turbines, contact Fusion Babbitting. Our certified materials, precise machining, and fast turnaround help you boost performance and reliability. Request a quote today. Call 414.645.5800 or 800.613.5118, or email sales@fusionbabbitting.com. We are ready with 24 hour emergency service and nationwide shipping to support your next outage or upgrade.
