Innovations In Bearing Technology For High Performance Applications

The balance between research and practical application ensures that market trends and environmental considerations are integrated into our new solutions:  NBC

Dr. Lokesh Agrawal
Chief Technology Officer
NBC Bearings

Q. What specialized bearing designs are used for challenging sectors such as aerospace, automotive, and renewable energy?

In the aerospace sector, bearing designs prioritize very high reliability with application-specific unique features. The materials and their processing are distinct to meet the stringent demands of aerospace applications. In the automotive industry, energy efficiency is a major focus, as reducing friction in bearings directly impacts overall vehicle efficiency. In the renewable energy sector, reliability and durability is paramount due to the high cost of downtime.

NBC achieves these through optimized roller/race contact, specialized finishes, cage materials, and coatings, advanced sealing solutions, such as triple lip seals and cassette seals, protect against dirt, water, and contaminants, which is especially critical in off-highway applications. Additionally, minimizing noise and vibration is crucial, which NBC manages by controlling geometrical tolerances and special surface finishes. To support high-speed operations, especially with the emergence of electric vehicles, NBC incorporates special cage designs and optimized ball-race contacts.

NBC uses specialized steel grades and defines its own steel cleanliness standards to meet industry requirements. The company also provides power-dense solutions that optimize space while maintaining load capacity and performance. Coatings such as black oxide and tungsten carbide help combat roller skidding and wear under fluctuating load conditions, while corrosion-resistant coatings like thin dense chrome protect against harsh environmental conditions. NBC is also developing remote condition monitoring devices to ensure continuous performance and minimize downtime.

Q. How does NBC overcome technical challenges in bearing applications for high-temperature, high-load, and corrosive environments?

To overcome technical challenges in high-temperature, high-load, and corrosive environments, NBC employs advanced materials and innovative design strategies. Bearings used in extreme conditions must retain their lubrication properties and structural integrity even at elevated temperatures. This is achieved through the use of high-performance alloys, ceramics, and specialized heat treatments that provide dimensional stability. For high-load applications, NBC incorporates robust load-bearing geometries and optimized surface treatments and uses low-carbon alloys to achieve impact toughness. In corrosive environments, apart from coating the use of stainless steel or hybrid bearings with ceramic balls enhances durability. Additionally, specialized lubricants, such as solid lubricants or high-temperature oils, are used to extend the life and reliability of bearings under these demanding conditions.

Q. What recent advancements have been made in materials and coatings to enhance bearing durability and performance?

Recent advancements in materials and coatings, such as the use of steel alloys and ceramics combined with specialized coatings like carbide/carbon, self-lubricating coatings, and nano-lubricants, have significantly improved the durability and performance of bearings. These innovations are particularly impactful in critical applications across domain, where enhanced load-bearing capacity, longer service life, lower torque, and increased resistance to wear, corrosion, and high temperatures are essential. As a result, bearings are now more reliable and efficient, capable of meeting the high demands of modern technologies, including electric drivetrains, high-speed motors, gas turbine etc.

Q. What measures are taken to ensure precision and reliability in bearings for critical applications?

To achieve high precision in bearings for critical applications, NBC employs specialized machinery with enhanced rigidity, high-precision air bearings, air-floating guides, and positioning detection systems. In-process gauging and clean cutting/cooling fluids contribute to precision, while environmental controls like constant temperature, vibration isolation, and damping are also maintained. For reliability, NBC uses cleaner steels such as VIM/VAR and vacuum heat treatments to produce scratch- and dent-proof rolling surfaces. A 100% non-destructive testing (NDT) process ensures quality, and special coatings or platings are applied based on application needs. Depending on the environmental conditions, specialized materials such as 440C, M50, M50NIL, and cobalt alloys are used.

Q. What role does R&D play in driving innovation and meeting industry-specific demands at NBC?

R&D at NBC plays a crucial role in developing innovative solutions that cater to the specific needs of different industries. Recognizing that no single solution fits all, each application is carefully assessed, and tailored features are added while maintaining the same overall design envelope. NBC invests in building capabilities, capacity, and infrastructure to support ongoing research & development. The balance between research and practical application ensures that market trends & environmental considerations are integrated into new solutions. A well-defined innovation process, supported by a reward system, encourages continuous improvement and the development of cutting-edge technologies.”