Durasol HDFP E
Case Study
An American-owned, multinational manufacturer of aerospace fasteners and components entered into a process of modernisation of its production facility. It wanted to move away from its traditional manufacturing methods to state-of-the-art high speed, and high-pressure CNC machines which would require water-soluble metalworking fluids.
BACKGROUND
With manufacturing partners such as Rolls Royce, this blade manufacturer was using an “approved” fully synthetic fluid on its twin-wheel creep feed grinding application and the Rolls Royce developed viper grinding. Originally developed by Rolls Royce for safety-critical components in aero-engines, VIPER is a 5-axis high-speed grinding machine capable of machining some of the toughest materials, including nickel-based superalloys. However, this state of the art manufacturer believed they needed more from their fluid to support their continued growth.
Traditional lathes and machining centres had been previously used in its production of Aero Alloy fasteners with materials including Inconel and Titanium. A ten million pound capital investment program meant they could introduce high pressure/high-speed Nakamura lathes. The decision was made to increase production capabilities through faster cycle times, which in turn would make the customer more profitable and more competitive.
Previously, they had used a traditional low foam, chlorine-free semi-synthetic fluid, but a change in HSE focus and the dramatic increase in machining capabilities now required a formaldehyde-free, ester-containing fluid.
Teklube TS was approached for its expertise and in-house chemists to help formulate a state of the art high-performance, formaldehyde-free fluid. The criteria involved producing a grade capable of working in high pressure (80-100 bar), long cycle time conditions on Inconel and Titanium, whilst complying with RPS917, RRP5900, Safran PCS-4001 and all other Aerospace Manufacturing guidelines. It needed to be:
Free from Formaldehyde
Based on high levels of synthetic esters
Chlorine, NP Ethoxylates (Free)
Secondary Amines (Free)
Ultra-low foam / low misting characteristics
Low top-up rate
Significant cost reduction
Operator friendly
Environmentally respectable
Meets Boeing, Airbus & Rolls Royce requirements for validation
Durasol HDFP E Details
Unrivalled cutting performance allows the grade to be used in all types of arduous manufacturing applications. The blend of performance additives provides outstanding surface finish and tool life on all types of aluminium, yellow metals and both ferrous and non-ferrous materials. The unique formulation prevents scum and soap formation associated with more reactive materials. The product has outstanding tramp oil rejection properties which means excellent cleanliness of the machine tool can be maintained.
Suitable for use in both soft and hard water, and for use on a wide range of difficult materials. The product is truly a multi-metal fluid and is the perfect choice for all modern manufacturing, including automotive, aerospace and high end manufactured components.
The unique low foam emulsifier system does not rely on traditional anti-foams for foam control. The emulsion, when in use, produces 50% less foam compared to similar emulsion types with a 50% repeatable rapid increase in foam collapse. To be used in both soft and hard water conditions from 0ppm – 750ppm.
Typical Physical Properties
| Appearance | Amber Liquid |
| Emulsion Type | Milky White |
| Foaming Tendency @ 5% emulsion in 50ppm | Nil foam after 5 seconds |
| Specific Gravity | 0.97 typical |
| pH @ 5% | 9.4 typical |
| Refractometer Factor | 1 |
| IP 287 Corrosion Brak Point, % Volume | 2.0 |
| Reichert Lubricity Characteristic at 10% dilution | |
| Noise Reduction (Metres) | 8 |
| Oil Content /Ester Content | 45% / 25% |