Grade 5 titanium (Ti-6Al-4V) is a workhorse alloy for industries that demand strength, reliability, and precision. Its exceptional strength-to-weight ratio and corrosion resistance make it indispensable in aerospace, medical, and automotive manufacturing.
However, those same properties make milling titanium one of the most demanding tasks in modern machining. Titanium’s low thermal conductivity means heat generated during cutting stays trapped at the tool-workpiece interface. This leads to edge softening, diffusion wear, and premature tool failure. Combined with high cutting forces and poor chip evacuation, the result is shortened tool life, rough surface finishes, and slower cycle times.
Traditional flood coolants and oil-based MQL systems can help to some extent, but at higher speeds they often can’t remove heat fast enough or maintain consistent lubrication at the microscopic level. That’s where the next generation of coolant strategies comes in.
Fusion Coolant’s Pure-Cut® system harnesses supercritical CO₂ (scCO₂)(a state where CO₂ behaves like both a gas and a liquid) to deliver targeted cooling deep into the cutting zone. When combined with Minimum Quantity Lubrication (MQL), this hybrid approach provides both powerful heat removal and molecular-level lubrication without leaving residue or waste.
As detailed in the peer-reviewed study High-Speed Milling of Ti-6Al-4V under a Supercritical CO₂ + MQL Hybrid Cooling System, this technology dramatically improves tool life, cutting forces, and surface quality compared with traditional methods.
The 2022 research confirms that using scCO₂ + MQL as a hybrid cooling and lubrication method delivers measurable performance improvements in high-speed titanium milling:
The study also noted the system’s “sub-zero cooling” effect: the rapid, precise delivery of supercritical CO₂ with MQL oil droplets effectively reduced heat generation and plastic deformation in the cutting zone, leading to better machinability, higher productivity, and cleaner operations.
Fusion’s Pure-Cut® system takes these findings from the lab to the production floor. By delivering scCO₂ through the spindle and tool, it reaches confined geometries and removes heat on contact. The precision-metered MQL mist creates a friction-reducing film that further stabilizes the cutting process, all without flooding the workpiece in oil or coolant.
Benefits for manufacturers include:
This clean, dry process supports sustainable manufacturing while enabling faster machining of critical titanium components.
Adopting advanced cooling doesn’t require overhauling your machines. Pure-Cut® is designed for seamless integration with existing CNC equipment, allowing shops to modernize without downtime or complex retrofits.
From initial tank setup to system calibration and cutting-parameter optimization, Fusion Coolant provides a turnkey solution that ensures consistent performance and maximum ROI.
For engineers and manufacturers working daily with titanium, even marginal performance gains translate into significant savings and competitive edge. Supercritical CO₂ + MQL technology delivers precision, sustainability, and productivity—all while extending tool life and enhancing part quality.
With Fusion Coolant’s Pure-Cut®, shops can machine Grade 5 Titanium faster, cleaner, and smarter — turning one of manufacturing’s most challenging materials into an opportunity for growth.
Learn how Fusion Coolant’s Pure-Cut® system can help your shop reduce costs, increase throughput, and achieve higher-quality titanium components.
Contact us today or explore our technical resources to learn more.