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TRIBOLOGICAL COATINGS BUSHINGS SUPPLIER

2018-10-06

VIIPLUS: Redefining Industrial Efficiency with Custom Tribological Bushings for Smelting & Casting Machinery


The Global Landscape of Self-Lubricating Bearings

The self-lubricating bearings market is dominated by giants like the U.S.’s GGB, Japan’s Sankyo Oilless, and Daido Metal, which hold strong positions in aerospace, automotive, and transportation. However, VIIPLUS has emerged as China’s leading exporter of high-performance tribological bushings, carving a niche in heavy industries like smelting and metal casting machinery. With advanced coatings, bespoke designs, and cost-effective solutions, VIIPLUS competes globally while addressing unique challenges in extreme industrial environments.


Why Smelting & Casting Machinery Demand Specialized Bushings

Smelting and casting processes involve extreme conditions:

  • High temperatures (up to 1,000°C in furnaces).

  • Heavy loads from molten metal handling.

  • Corrosive atmospheres due to chemical reactions.

Traditional lubricated bearings fail here due to grease degradation, contamination risks, and frequent maintenance. VIIPLUS’s self-lubricating bushings solve these issues with:

  • Solid lubricants (e.g., PTFE, graphite) embedded in metal matrices.

  • Tribological coatings that reduce friction without external grease.

  • Custom alloys (bronze, copper-based composites) for thermal stability.


VIIPLUS Bushings in Smelting & Casting: Key Applications

1. Continuous Casting Machine Raceways

Raceways guide molten metal into molds, requiring bushings that withstand:

  • Cyclic thermal stress from rapid heating/cooling.

  • Abrasion from metal flow.

VIIPLUS Solution:

  • Bronze-PTFE Composite Bushings: Combine copper’s thermal conductivity with PTFE’s self-lubrication.

  • Durability: 2–3x longer lifespan than standard bronze bushings.

2. Automatic Mold Forming Machines

Precision alignment is critical for mold integrity. VIIPLUS provides:

  • Wear-resistant bushings with molybdenum disulfide (MoS2) coatings.

  • Low-friction designs to reduce energy consumption by 15–20%.

3. Ladle Turrets & Molten Metal Handling

  • High-load bushings with steel-backed composites for shock absorption.

  • Corrosion-resistant coatings to withstand slag and molten metal splatter.


VIIPLUS vs. Traditional Bushings: A Comparative Breakdown

Parameter VIIPLUS Self-Lubricating Bushings Traditional Lubricated Bushings
Maintenance Zero lubrication required Frequent greasing needed
Temperature Resistance Stable up to 350°C (short-term 500°C) Fail above 200°C (grease breakdown)
Contamination Risk None (no grease) High (grease attracts dust/debris)
Lifespan 20,000–30,000 hours 8,000–12,000 hours
Customization Tailored coatings/materials for each application Limited material options

Tribological Coatings: The Science Behind VIIPLUS’s Superiority

VIIPLUS integrates advanced coatings to enhance bushing performance:

1. PTFE-Based Coatings

  • Friction Coefficient: As low as 0.05–0.10 (compared to 0.15–0.25 for uncoated bronze).

  • Applications: Low-speed, high-load scenarios (e.g., ladle tilting mechanisms).

2. Molybdenum Disulfide (MoS2)

  • High-Temp Stability: Effective up to 400°C.

  • Use Case: Continuous casting machine guide rollers.

3. Composite Polymer Coatings

  • Self-Healing Properties: Minor scratches are filled by lubricant reservoirs.

  • Ideal For: Mold forming machines with repetitive linear motion.


VIIPLUS vs. Global Competitors

While GGB and Daido focus on aerospace/automotive, VIIPLUS targets heavy industrial sectors with cost-efficient, heavy-duty solutions:

Aspect VIIPLUS GGB (U.S.) Daido (Japan)
Price 20–30% lower Premium pricing Premium pricing
Lead Time 4–6 weeks (custom orders) 8–12 weeks 10–14 weeks
Specialization Smelting, casting, construction machinery Aerospace, automotive Automotive, robotics
Material Range Bronze, copper, steel-polymer composites High-performance polymers Aluminum alloys, specialty steels

Case Study: Boosting Efficiency in a Steel Mill

A Chinese steel mill replaced traditional lubricated bushings in its continuous casting line with VIIPLUS’s copper-PTFE composite bushings. Results included:

  • 45% reduction in downtime due to maintenance.

  • 30% lower energy costs from reduced friction.

  • Zero lubricant contamination in molten steel.


The VIIPLUS Advantage: Custom Solutions for Extreme Environments

  1. Material Selection:

    • Bronze-Based Bushings: Ideal for high thermal loads.

    • Steel-Backed Composites: For shock resistance in ladle handling.

  2. Geometry Optimization:

    • Flanged, cylindrical, or spherical designs to fit machinery.

  3. Export-Ready Quality:

    • 57% of VIIPLUS products are exported, meeting ISO 9001 and ASTM standards.


Future Trends: Smart Bushings for Industry 4.0

VIIPLUS is pioneering sensor-equipped bushings for predictive maintenance in smelting plants. These innovations include:

  • Embedded wear sensors to alert teams before failure.

  • IoT integration for real-time performance monitoring.


Partner with VIIPLUS

From design to delivery, VIIPLUS delivers engineered solutions for the most demanding industrial applications.

Contact VIIPLUS Today:


Engineered for Heavy Industry. Built to Endure.