Part 5 of our Aerospace series of case studies looks at a year-long trial Castrol were invited to take part in to determine the best and most cost effective fluid for US based aerospace and bearing manufacturer.

To identify the best possible solution, the client conducted a year-long trial involving Castrol, Blaser, Chemetall, Fuchs, and Qualichem. Castrol Hysol SL 45 XBB was recommended and outperformed its rivals in every aspect as well as helping the company slash its operating costs. During the year-long trial, Castrol Hysol SL 45 XBB increased tool life by 35% and reduced fluid usage by 53%.

Read the case study summary to see how moving to Castrol Hysol SL 45 XBB achieved these figures.

Sector          | Industrial

Sub-sector     | Aerospace Manufacturing

Application  | Machining

Product       | Castrol Hysol SL 45 XBB

Background

A major US manufacturer invited us to take part in a year-long trial to determine the best, most cost-effective cutting fluid for its operations. We recommended Castrol Hysol® SL 45 XBB, putting it to the test alongside several of our competitors’ products. Castrol’s high-performance fluid came out on top, outperforming its rivals in every aspect and helping the company slash its operating costs.

Challenge

The subject of the study is a major aerospace and bearing manufacturer, based in the US. The company was looking for a new cutting fluid that would help to improve its total operating costs.

To identify the best possible solution, the client conducted a year-long trial involving ourselves and our competitors – Blaser, Chemetall, Fuchs, and Qualichem.

The minimum fluid requirements were aerospace approval, global availability, and semi-synthetic chemistry. The requirements for performance included multiple machined materials, Inconel, stainless steel, Stellite, titanium, tungsten, and aerospace aluminium.

Solution

The process began with an in-depth survey of the plant, conducting a thorough review of the client’s machines, parts and processes. Once a clear picture had been of the specific requirements had been established, Castrol Hysol® SL 45 XBB was recommended – a high-performance soluble metalworking fluid specifically designed for machining multiple metals and alloys. To ensure the trial went as smoothly as possible, a fluid control plan was provided so the client could accurately monitor and maintain the coolant systems. The client implemented fluid-related best practices with its existing coolant and used this as a baseline for the trial.

Outcome

The results were emphatic. Castrol Hysol® SL 45 XBB outperformed its competitors across the board. Throughout the year-long trial, it consistently ran at the lowest concentration of all the fluids – an impressive 4% on aerospace aluminium and just 8-10% on all other metals. Its unique formulation package helped to enhance tool life and improve surface finish, and its biocide-free formula eliminated all operator safety and dermatitis concerns. In all, by switching to Castrol Hysol® SL 45 XBB, the client stood to make average cost savings of $0.21 per production hour per material, for a net overall cost reduction of nearly 73%.

Advice

To discuss your industrial lubricant needs or to see what we can do for you. Contact Kernow Oils us on 01736 757 002, email at info@kernow-oils.co.uk or visit our website at https://www.kernow-oils.co.uk/products-category/industrial-lubricants/