From Damage to Functionality: Remanufacturing of Thrust Roller Bearings by Tailored Forming

Axial and radial rolling bearings are critical components in various machines, particularly in large‐scale applications such as mining and heavy machinery. Failures in these bearings can cause significant operational downtime and high replacement costs. Common failure modes include plastic deformation, abrasive wear, insufficient lubrication, and fatigue, necessitating efficient repair strategies. This article investigates the tailored forming process chain for repairing axial bearing washers, focusing on plasma‐transferred arc deposition welding. The repair process involves removing damaged areas, welding, and machining to nominal size. Materials used include a novel alloy and commercially available powders. The repaired bearings undergo rigorous testing, including scanning acoustic microscopy for weld quality assessment and fatigue tests on FE8 test rig. Results indicate that the newly developed alloy exhibits higher fatigue life despite its lower hardness compared to AISI 52100 and AISI 4140 steels. The repaired bearings achieve a service life comparable to new bearings, with the welding process quality significantly impacting longevity. Tribological tests show the new alloy's superior wear resistance, suggesting its potential for extending the service life of repaired bearings. The study concludes that tailored forming processes, combined with optimized welding techniques, can effectively repair rolling bearings, reducing costs and downtime while enhancing performance.