Castrol solves a sticky problem for Flight Refuelling

Citation

(2003), "Castrol solves a sticky problem for Flight Refuelling", Aircraft Engineering and Aerospace Technology, Vol. 75 No. 3. https://doi.org/10.1108/aeat.2003.12775cab.004

Castrol solves a sticky problem for Flight Refuelling

Castrol solves a sticky problem for Flight Refuelling

Following the commissioning of 15 new CNC machines, Flight Refuelling Ltd found that sticky deposits left by a cutting fluid threatened to invalidate the warranties. When their fluid supplier could not solve the problem, Castrol was called in.

Flight Refuelling Ltd, part of Cobham PLC, specialises in the manufacture of aerospace engineering components and systems. The company is prominent in air-to-air refuelling and the supply of fuel system components to commercial aircraft manufacturers.

The company's machine shops at Wimborne in Dorset, UK, employs 300 staff and accommodates more than 200 machines, including 15 new CNC machines that were plagued with sticky deposits from a cutting fluid following commissioning.

Andy Wills, Flight Refuelling Facilities and Safety Manager explains, "The machine manufacturer complained that their engineers were finding sticky deposits building up in critical areas of the new machines during servicing and as this could invalidate the warranty and service agreements, we asked our coolant supplier to investigate."

Despite conducting cutting trials, the coolant supplier was unable to solve the problem and Andy was advised by the machine manufacturer to call in Castrol, who had been training their service engineers as part of a coolant awareness programme.

When Castrol was invited to investigate the problem they began by sampling the water supply and recommended two cutting fluids – Hysol XF and Alusol XTH. James Bayliss, Castrol's Specialised Industrial Sales Manager, explains the choice of cutting fluid.

"As Flight Refuelling is machining aerospace components in light aluminium alloys, mild and stainless steels and steel alloys such as inconel and nimonic, it was important to specify a chlorine-free cutting fluid to avoid the stress fracturing that chlorine can cause in the surface of alloys."

During the extensive trials that followed Castrol provided technical support and product information and Flight Refuelling conducted operator health surveillance and monitored tool life to ensure that solving one problem did not create another.

The trials were successful and the new CNC machines were given a clean bill of health, making the Castrol fluids very popular with the machine operators, who were also involved in the trials and the final selection process.

"It was important that everyone using the fluids liked them," says Andy. Castrol was then awarded the contract to supply cutting fluids for all the machines and began working with the company's maintenance team, providing them with sump cleaners and training them in coolant awareness, health and safety issues and operational requirements.

Commenting on the results, Andy says maintenance had previously meant cleaning out the sumps to maintain the condition of the fluid. "Now," he says: "Fluid life has increased to such an extent that we have to implement a sump cleaning schedule to ensure that we remove the swarf and fines regularly!"

He also reports that fluid waste has been significantly reduced, resulting in much lower disposal costs and contributing to the company's BS 14001 continuous improvement programme. And useful additional savings have been made since extending the Castrol contract to include lube oil purchases.

His final comment is also reassuring; "Deliveries are on time, cutting fluid is always available ... and Castrol collects the empty drums!"

Details available from: Castrol (UK) Ltd. Tel: +44 (0) 1793 452356; Fax: +44 (0)1793 486083; E-mail: thrussc@castrol.com; Web site: www.castrol.com