A leading manufacturer of vacuum deposition equipment recently turned to TriStar to solve a persistent bearing problem. Their equipment is uniquely versatile, handling a wide range of deposition materials and processes for both military and industrial customers. From optical and protective coatings for defense applications to high-value reflective coatings for advanced lighting, this equipment delivers precision results in highly controlled environments.
The Core Problem: Lubrication Added Cost and Downtime
At the heart of the machine is a large carousel wheel designed to process multiple parts per cycle, some as long as 18 inches. The central spindle bearing was historically lubricated with vacuum-compatible greases capable of withstanding temperatures above 450°F. However, these lubricants required routine reapplication, causing costly downtime and maintenance interruptions.
A Self-Lubricating Solution with Proven Results
TriStar’s engineering team quickly identified a more reliable path forward by leveraging our deep experience in vacuum chamber environments. Our EMD group operates several chambers in active service, giving us firsthand knowledge of what works and what doesn’t. The solution combined a PTFE-based material enhanced with MoS2 for its self-lubricating properties. To ensure consistent lubrication to the balls and races, we engineered a custom ball retainer made from our Beraloy 955 — a high-performance material capable of operating continuously at 550°F.
Beraloy 955’s dual lubrication mechanism eliminates the need for added lubricants. During operation, a thin film of PTFE and MOS2 transfers to the bearing surfaces, creating a stable, self-renewing lubrication layer. This technology drastically reduces wear while delivering long-term performance with no maintenance required.
Customer Benefits that Make a Measurable Difference
Since adopting TriStar’s design, the customer reports maintenance costs have dropped by more than 40%. The longevity and stability of this solution have improved uptime and performance for their end users, reaffirming the value of TriStar’s collaborative, problem-solving approach to bearing challenges in extreme environments.
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