In our final part of our Aerospace series of case studies we look at an aerospace component manufacturer in the US specialising in 4 and 5 axis milling. Operating 42 machines working aluminium, titanium and high-temperature alloys, the manufacturer was experiencing multiple issues with their metalworking fluid including foam-overs, high usage, elevated concentration levels, and residue build-up on equipment. Following the switch to Castrol Hysol SL 45 XBB the results were impressive, with all issues seeing dramatic improvement, alongside significant cost savings. Castrol Hysol SL 45 XBB reduced coolant use by 20% saving the manufacturer over $20,000 annually.

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

Sector          | Industrial

Sub-sector     | Aerospace

Application  | Milling and Turning (General Machining)

Product       | Castrol Hysol SL 45 XBB

Background

An aerospace component manufacturer was experiencing multiple issues with their metalworking fluid. These include fluid foam-overs, high usage, elevated concentration levels, and residue build-up on equipment. Upon evaluation, Castrol Hysol SL 45 XBB was recommended. The results were impressive, with all issues seeing dramatic improvement, alongside significant cost savings.

Challenge

Specializing in 4 and 5-axis milling, an aerospace manufacturer operating 42 machines – working aluminium, titanium and high-temperature alloys – was encountering multiple issues with their metalworking fluid. Issues included fluid foam-overs, high usage, elevated concentration levels, and residue build-up on equipment. These problems were disrupting production and driving up costs due to the need for tank-side coolant additives. Some components have a 7-day cycle time to complete a single part, so the customer needed a reliable coolant to provide uninterrupted performance.

Solution

After understanding the customer’s challenges, Castrol Hysol SL 45 XBB was recommended – approved for use by Boeing (BAC 5008 approval). A high-performance, soluble metalworking fluid which is formulated without boron, a formaldehyde-releasing agent and chlorine.

Low foaming in recommended water conditions, it contains an additive package that may help to enhance machining performance and surface finish. Suitable for large central systems and single sump machines, it also provides good product stability which helps to lower the overall operational costs.

Outcome

The client was very happy with the results, experiencing no foam issues or residues. Hysol SL 45 XBB delivered value across the board, obtaining better part finish, reduced usage, lower maintenance costs, and high operator acceptance. Cleanliness was also drastically improved, allowing operators to see through machine windows. Alongside the elimination of coolant additives, the customer managed to achieve annual savings of almost $20,000 and an expected sump life of over 12 months.

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/.