Ethanol mist for cutting aluminium

[magicniner]

Straight Paraffin works nicely for soft aluminium.
90/10 to 70/30 Paraffin to 20 weight oil gives good results with a wide range of materials.
You will still need extraction for any mist system which creates any airborne contamination in your workshop,

- Nick

[Tenson]

I think it's methanol that makes you blind rather than ethanol. Please let me know if you find a source for ethanol I might like to try it for the occasional ali cutting (seems like you can get bio-ethanol for fireplaces). The mess of oil or water is an issue for me too.

Both methanol and also isopropyl alcohol are easy to get hold of but both are very bad for your health so make damn sure you don't breath too much. As little as 250ml consumed can kill.

As for WD40 seperating from the water you need to get a water soluble oil. People call it 'cutting oil' and mixed with water 'white water'. http://www.ebay.co.uk/itm/G-P-Solubl...3D111574149025

[magicniner]

As little as 250ml consumed of either can kill.

Evaporated into air you could make a huge explosion before you got anywhere near exposing yourself to 250ml ;-)

[cropwell]

Just a further cautionary note - Ethanol burns with a near invisible flame.

[komatias]

is this the article the OP is refereing to?

http://www.mmsonline.com/articles/al...ndly-machining

Still not a particularly safe way of going about it. I wonder if Krytox would be good for the application though. Low viscosity, low evaporation and water based too.

[magicniner]

is this the article the OP is refereing to?

http://www.mmsonline.com/articles/al...ndly-machining

I doubt it as extraction, containment and fire suppression equipment are stated to be implemented for alcohol use, you wouldn't need to worry about the smell in the workshop if that was or was intended to be the case,

- Nick

[Billythefish]

You can definitely do it. You probably also need to run it in conjunction with some sort of extraction, filter, return system. A few things to consider. First of all you dont use much with a minimum quantity system. You dont want to be breathing to much so it is sensible to suck out of the work area and filter/recondense. You could make a system to do this. There are many advantages....

[PaisleyPCdoctor]

I don't know why you are trying so hard to find pure ethanol.
Pure ethanol is subject to alcohol tax as it can be used to make alcoholic drinks.

To avoid this tax, the ethanol can be spiked with about 5% Methanol making it UNDRINKABLE. hence the term 'methylated spirit' or 'denatured ethanol'.

Methylated spirit smells almost identical to ethanol. Methylated spirit purchased in pharmacy or supermarket is further spiked with purple dye, bitrex and some horribly smelling crap that I forget the name of. Obviously to stop idiots drinking it.

You can easily buy methylated spirit without the stinky additives etc.

Small quantities vaporised with decent ventilation would be fine (healthwise), If you went crazy with it, you'd get high as a kite and or start a fire. I'd worry about electric motor in fume extraction equipment.

It may be possible to dilute the alcohol with water to decrease risks?

[matt-b2]

Thanks for the responses.

is this the article the OP is refereing to?

http://www.mmsonline.com/articles/al...ndly-machining

Still not a particularly safe way of going about it. I wonder if Krytox would be good for the application though. Low viscosity, low evaporation and water based too.

I did come across that article whilst I was researching into the matter.

I appreciate ethanol has its dangers - I think, first and foremost, I need to get the ventilation in my shop sorted, no matter what I'm using for coolant.

[Robin Hewitt]

The problem with ethanol is that the Government tax it to hell and back.

If you cut it with methanol to make it poisonous and pyridine to make you throw up, you can escape the tax.

You could spray it on to a tool tip but I have to wonder why. Are you sure you have the right chemical?