Metalworking in the aerospace sector has always presented unique challenges. Cutting fluids face unusually stringent manufacturer approval processes, and the metals used in the industry themselves are some of the hardest to work with. Because aerospace is driven by hard metals like titanium and nickel-based alloys like Inconel®, these materials require simultaneous lubricity and cooling to be effectively cut, forcing operators into a constant trade-off of increased time or material use with the product currently available.
With more than 70 cutting fluid approvals in our product line-up, we set out to innovate and address this need.
The First Neo-Synthetic Coolant
TRIM™ HyperSol™ 888NXT was specifically introduced to the market to solve the aerospace industry’s complex challenges. However, in the process, this resulted in an entirely new category of cutting fluid to the metalworking industry.
Previously confined to neat oils, soluble oils, microemulsions, synthetics and semi-synthetics, each category was recognised for its unique strengths as either a high-lubricity fluid with limited cooling capabilities or as an efficient cooling fluid that’s less efficient as a lubricant. Immediately, HyperSol 888NXT stood out with its ability to provide an incredibly high cooling rate while exhibiting an unparalleled level of lubrication. This powerful combination was never before achieved in a single cutting fluid before introducing this product.
This new category of neo-synthetic cutting fluid opens the door for major transformations and operational improvements for shops specialising in aerospace manufacturing and beyond.
Lower Material Consumption
One of the standout features noticed by operators is how far a small amount of the neo-synthetic coolant goes.
Much less needs to be reapplied throughout the day to maintain cutting fluids at the concentration for optimal machine performance. For some customers, HyperSol 888NXT has reduced coolant concentrate consumption by 50 percent.
Using less product translates directly into less storage space needed for supplies, a smaller budget for cutting fluid and major cost savings from less fluid disposal. In fact, one customer lowered coolant spend by 48 percent.
Increased Productivity
Neo-synthetics allow operators to run machines quicker, without the risk of damaging tools or work material. This increased throughput massively enhances operational productivity, allowing more parts to be processed per hour, which then substantially lowers labour costs and improves machine utilisation rates.
The unique combo of high lubricity and high rate of cooling leads to unprecedented longevity of cutting tools. A European manufacturer specialising in high-precision parts for the aerospace industry saw a 234 percent increase in tool life after switching to neo-synthetic HyperSol 888NXT.
Plus, one of the hallmarks of neo-synthetics is they produce less foam. Less frequent cleaning combined with fewer tool replacements increase machine uptime and productivity.
Neo-synthetic coolants like HyperSol 888NXT may be instrumental in powering and maintaining 24/7 machining operations.
More Environmentally Friendly
HyperSol 888NXT was officially recognized as a USDA Certified Biobased Product. As a category, neo-synthetic coolants are expected to be more environmentally friendly than other emulsion (soluble oil) classes because of the ingredients required to create the unique combination of attributes they are trying to achieve. Master Fluid Solutions™ created HyperSol 888NXT without chemicals such as sulfur, mineral oil and chlorine.
Increasingly, machining operations of all sizes and types are launching sustainability and green initiatives within their shops. In addition to the cost savings and wide-application possibilities, our neo-synthetic product is used to mitigate manufacturing harm to the environment.
Free of oil and petroleum products, HyperSol 888NXT greatly reduces smoke and odors, improving the environment of the shop space itself. The HyperSol also offers superior corrosion protection with less pronounced residues when compared to full synthetic products.
Innovation Beyond Aerospace
Due to strict industry standards, when aerospace manufacturers approve a cutting fluid for their operation, it signals the product has potential for a wide array of applications.
Regardless of industry, HyperSol 888NXT extends tool life, reduces coolant consumption, improves shop environments and supports sustainability initiatives. Beyond aerospace, the neo-synthetic is proving useful for automotive metalworking operations and operations focused on grinding and cutting super-abrasive metals.
Want to learn how neo-synthetics can transform your operation? Contact Master Fluid Solutions at [email protected].
