In aerospace machining, every detail matters. Components made from alloys like Inconel® 718, titanium, tantalum, niobium, molybdenum and tungsten must meet strict performance standards under extreme conditions. From turbine blades in jet engines to propulsion systems and high-temperature structural components, there’s no room for error.
Machining these alloys is notoriously difficult due to their strength, heat resistance, and tendency to work-harden. That’s why aerospace manufacturers are turning to Halocarbon Metalworking Fluids (MWFs). Independent testing shows Halocarbon fluids consistently deliver longer tool life, smoother finishes, and faster cycle times than leading competitive machining fluids—across the full spectrum of mission-critical aerospace metals.
Aerospace Applications Across Metals
Halocarbon MWFs have demonstrated measurable advantages in machining key aerospace alloys:
- Nickel Alloys (Inconel® 718, Inconel® 625, Haynes 230): Used in turbine blades, combustion components, and exhaust systems. Halocarbon MWFs improved tool life, surface finish, and cycle time.
- Titanium Alloys (Ti-6Al-4V, Ti-6Al-2Sn-4Zr-2Mo): Critical for airframes, fasteners, landing gear, and engines. Halocarbon MWFs showed 50% lower coefficient of friction in twist compression testing and no corrosion under ASTM 483 and 945.
- Refractory Alloys (Tantalum, Niobium, C103, TZM, Tungsten, Molybdenum): Used in propulsion systems, rocket nozzles, and heat shields. Testing showed 200–500% reductions in surface roughness and up to 5x improvements in tool life.
- Cobalt Chrome (CoCr): Increasingly used in additive manufacturing for turbine blades and wear-resistant parts. Halocarbon MWFs delivered consistent surface finish and chip control.
Independent Test Data:
Halocarbon has been working with a broad range of machining companies, defense contractors, academic labs, and independent testing service organizations. The results from our open innovation studies are in. The data speaks for itself. Halocarbon MWFs deliver clear advantages to machining the difficult-to-machine materials common to the aerospace industry.
Nickel 718 (Inconel® 718): Halocarbon worked with Kratos SRE to perform a definitive head-to-head study of a Halocarbon MWF against a leading competitive control fluid. In this study, nickel 718 was machined using 13 discrete machining operations. The results below summarize the key findings from that study.
| Operation | Halocarbon MWF 32 | Control Fluid |
| Tapping | 17 out of 24 holes completed | 0 out of 24 holes completed |
| Bore Surface Finish | 11–12 µin Ra | 25–26 µin Ra |
| Cycle Time | 59 minutes | 70 minutes |
Titanium Alloys (Ti-6Al-4V, Ti-6Al-2Sn-4Zr-2Mo): Halocarbon studied the effects of its MWFs on the machining of titanium alloys. The data below show the summary of two different tests: (1) Twist Compression Testing, and (2) Titanium corrosion testing. The twist compression test is a method where two metal surfaces are pressed together under load while rotated and subsequently starved of fluid to simulate tool-workpiece friction. The coefficient of friction calculated in this test is a direct predictor of tool wear and heat generation during cutting. In this test, Halocarbon was able to directly compare the performance of two different titanium cutting fluids.
| Test | Halocarbon MWF 10 | Control Fluid |
| Twist Compression (COF) | 0.25 avg COF (50% lower) | 0.50 avg COF |
| Corrosion (ASTM 483 & ASTM 945) | No pitting, discoloration, or cracking | Susceptible to localized corrosion |
Tantalum (Refractory Alloys): Halocarbon, in collaboration with Lawrence Livermore National Lab (LLNL) conducted a test of Halocarbon MWFs in the machining of Tantalum components. The results below show the unmatched performance benefits of Halocarbon MWFs, and are consistent with the work shown on alloys such as nickel 718.
| Metric | Halocarbon MWFs | Competitor Fluids |
| Surface Roughness | 200–500% smoother | Baseline |
| Tool Life | 50% longer in roughing cuts | Shorter tool life |
Tungsten, Molybdenum, and Niobium (Including TZM and C103): Halocarbon has been collaborating with academic research groups and applied science incubators at the Georgia Institute of Technology. In these collaborations, Halocarbon MWFs have been tested against difficult-to-machine metals and alloys comprised of Tungsten and Molybdenum, including TZM and C103 (which. These results provide further proof of the advantage Halocarbon MWFs provide to machining.
| Metal / Alloy | Machining Fluid | Surface Roughness Sa (µm) | Halocarbon Advantage |
| C103 | Halocarbon MWF 32 | 1.135 | 21% |
| Control Fluid | 1.433 | ||
| Tungsten (W) | Halocarbon MWF 32 | 1.187 | 18% |
| Control Fluid | 1.452 | ||
| Tantalum (Ta) | Halocarbon MWF 32 | 1.457 | 24% |
| Control Fluid | 1.910 | ||
| TZM | Halocarbon MWF 32 | 0.795 | 26% |
| Control Fluid | 1.072 |
Operation: Side-milling. Tool: Kennametal HARVI I. Control Fluid: Acculube LB-1200
Why Halocarbon MWFs Make the Difference in Aerospace
For aerospace manufacturers, the performance advantages of Halocarbon MWFs translate directly into real business impact:
✔ Lower tooling costs across high-value alloys
✔ Higher first-pass yield and fewer rejected parts
✔ Reduced downtime and faster throughput on production lines
✔ Confidence in machining mission-critical alloys from Inconel® to titanium to refractory metals
The result is more efficient, reliable, and cost-effective production across the materials that matter most in aerospace.
Harness the Advantage for Your Machining Operations
Halocarbon MWFs aren’t just another machining fluid—they’re a proven performance enhancer across the toughest alloys in aerospace machining.