Developing a novel copper nano-based emulsified cutting fluid with antimicrobial and anticorrosion properties – an attempt for sustainability

Purpose This study aims to develop a copper nano-based emulsified cutting fluid (ECF) with enhanced thermal, antimicrobial and anti-corrosion properties. The study focuses on optimizing the water-to-Triton X-100 (W/TX) ratios and incorporating copper nanoparticles to improve the fluid’s overall efficacy in machining applications. Design/methodology/approach Various trial combinations were conducted to determine the optimal W/TX ratios. The as-prepared copper nanoparticles were dispersed in the cutting fluid to enhance its thermo-physical properties. The thermal conductivity, thermal stability and surface spreading capability were measured. Microbial studies identified prevalent microorganisms, particularly Mycobacterium immunogenum . To combat microbial contamination and corrosion, natural biocides ( ß -Ionine) and sodium dihydrogen phosphate (NaH 2 PO 4 ) were added. The corrosion inhibitor efficiency and overall performance were evaluated. Findings The inclusion of copper nanoparticles significantly improved the cutting fluid thermal properties, achieving a 51.12% enhancement in thermal conductivity and thermal stability. The surface spreading capability was enhanced with a contact angle of 52.48°. Mycobacterium immunogenum was identified as the most frequent contaminant. The addition of natural biocide ß -Ionine effectively addressed microbial contamination, while 1.4 ml of NaH 2 PO 4 improved the corrosion inhibitor efficiency to 66.94%. The Cu-W/TX cutting fluid demonstrated eco-friendly characteristics with notable antimicrobial and anti-corrosion benefits. Originality/value The research work improves ECFs by incorporating copper nanoparticles and optimizing surfactant ratios. It highlights Triton X-100’s potential as a cutting fluid base and the benefits of natural biocides, contributing to more sustainable, efficient fluids with significant environmental and industrial implications.