Defender Ultra metalworking fluid (MWF) is available for purchase from the Novohim online chemical products store.

Defender Ultra is a synthetic, water-miscible metalworking fluid concentrate designed for use on metal-cutting machine tools in both centralised circulation systems and local coolant supply. The product combines cooling, lubricating, cleaning and corrosion protection properties, ensuring stable performance of the working solution under real industrial conditions.

Unlike conventional oil-based emulsions, Defender Ultra is not only focused on machining efficiency, but also on cleaner machine operation, high biostability, stable solution performance, and reduced operational issues such as foaming, odour formation, deposits and system instability.

Advantages of Defender Ultra Metalworking Fluid

Using a synthetic metalworking fluid provides significant operational benefits:

• synthetic water-miscible metalworking fluid concentrate;
• high biostability under correct operating conditions;
• strong corrosion protection;
• effective cleaning properties;
• cleaner machine operation compared with conventional emulsion fluids;
• stable working solution;
• suitable for a wide range of machining operations;
• easy preparation and concentration control;
• suitable for both circulation systems and local applications.

Suitable Machining Operations

Defender Ultra is suitable for a wide range of metalworking operations where cooling efficiency, system cleanliness, solution stability and adequate lubrication are required.

Recommended applications:

• turning;
• milling;
• drilling;
• boring;
• grinding;
• honing;
• tool sharpening;
• gear cutting;
• bandsaw cutting.

The product is especially suitable for manufacturers who require a modern synthetic coolant rather than heavy oil-based fluids, offering stable performance, clean operation and simplified maintenance.

Suitable Materials

Defender Ultra can be used for machining:

• cast iron;
• carbon steels;
• medium and high alloy steels;
• stainless steels;
• aluminium;
• a range of non-ferrous metals and alloys, depending on the specific application.

For machining copper, brass or bronze, it is recommended to consider specialised products formulated specifically for non-ferrous materials.

How the Product Works

During machining, Defender Ultra forms a stable working solution that simultaneously cools the cutting zone, reduces friction and efficiently removes chips.

Thanks to its synthetic formulation, the fluid remains highly stable and helps prevent biological deposits from forming within the system.

Technical Specifications

Why Choose Defender Ultra

Selecting the correct metalworking fluid is not only about cooling performance. In practice, machine condition, coolant stability, system cleanliness, ease of maintenance, odour control, foaming behaviour, microbial resistance and corrosion protection are all equally important.

Defender Ultra has been developed specifically for these requirements. It delivers not only effective cutting-zone performance but also stable, predictable system operation over time.

Key Properties

Excellent cleaning performance

Defender Ultra ensures cleaner machine operation compared with conventional oil-based emulsions. This is essential where cleanliness, visibility, reduced deposits and easier maintenance are required.

Corrosion protection

The product contains a functional corrosion-inhibiting package that helps reduce corrosion risks on both machine components and workpieces when correct concentration and application procedures are followed.

High biostability

One of the most common issues in coolant systems is microbial growth, unpleasant odour, and fluid degradation.

Defender Ultra is formulated for high biostability and maintains performance when concentration and system hygiene are properly controlled.

Stable working solution

Its synthetic nature ensures a stable solution without the instability commonly associated with emulsion-based coolants.

Balanced performance

Defender Ultra provides a balanced combination of cooling, lubrication and cleanliness, making it suitable for a wide range of machining operations.

Where It Is Most Effective

Defender Ultra is particularly suitable where the following are required:

• versatility across machining operations;
• cleaner machine tool operation;
• stable coolant performance over time;
• easy concentration control;
• high biostability;
• corrosion protection;
• reduced maintenance issues in circulation systems.

Recommended Concentration

The working concentration depends on:

• machining type;
• material;
• cutting conditions;
• delivery system;
• water quality;
• system condition;
• cleanliness and corrosion protection requirements.

General guidance:

• low concentrations for light-duty operations;
• medium concentrations for standard machining;
• higher concentrations for heavy-duty operations, bandsawing, poor water quality or enhanced protection requirements.

Exact concentration should be confirmed through practical testing and manufacturer recommendations.

How to Prepare the Working Solution

To ensure stable performance, proper preparation is essential:

• use clean water;
• follow recommended concentration guidelines;
• do not mix with other fluids without compatibility testing;
• clean the system before switching products;
• monitor concentration during use.

Only working solution should be used for topping up machines — not plain water.

Important: the cost of the working solution is significantly lower than the concentrate (approximately 20× at 5% concentration).

Water Quality Requirements

Water quality strongly affects performance.

Important factors include:

• water hardness;
• mineral content;
• chemical stability;
• impurities.

Poor water quality may cause:

• unstable emulsions;
• sediment formation;
• foaming;
• reduced cleaning efficiency;
• weaker corrosion protection;
• reduced fluid lifespan.

Comparison with Conventional Emulsions

Compared with traditional emulsion coolants, Defender Ultra provides:

• cleaner system operation;
• reduced oil contamination;
• easier control of working concentration;
• improved stability;
• strong biostability;
• reduced risk of common system issues.

Defender Ultra vs Defender Ultra M

Defender Ultra is a universal synthetic coolant for general metalworking applications.

Defender Ultra M is a specialised formulation intended for non-ferrous metals, especially copper, brass and bronze.

The choice depends not on which is “better”, but on which is more suitable for the specific machining task.

When It May Not Be Suitable

Defender Ultra is not intended as a universal solution for extreme heavy-duty cutting conditions.

Where maximum extreme-pressure (EP) lubrication is required, specialised oil-based or dedicated high-performance fluids may be more appropriate.

Its strength lies in a balanced formulation:

• cooling;
• adequate lubrication;
• cleanliness;
• corrosion protection;
• biostability;
• operational stability.

Who It Is Suitable For

Defender Ultra is suitable if you need:

• synthetic machine coolant;
• water-miscible metalworking concentrate;
• coolant for turning, milling, drilling or grinding;
• coolant for bandsaw machines;
• corrosion-protective coolant;
• biostable circulation system fluid;
• a modern alternative to emulsion-based coolants.

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FAQ

What is Defender Ultra?

Defender Ultra is a synthetic water-miscible metalworking-fluid concentrate for metalworking, intended for preparing a working solution and use on metal-cutting machines.

What operations is Defender Ultra suitable for?

The product is suitable for turning, milling, drilling, boring, grinding, honing, gear cutting, tool sharpening, and bandsaw machining.

What metals can Defender Ultra be used for?

Defender Ultra is used for cast iron, steels, stainless steel, aluminum, and a range of non-ferrous metals, depending on the specific task.

Is Defender Ultra suitable for circulating systems?

Yes. The product is designed for stable operation in circulating systems and, when maintained correctly, provides good operational stability.

How does Defender Ultra differ from emulsion metalworking fluids?

The synthetic nature of Defender Ultra provides cleaner machine operation, good cleaning properties, high biostability, and a stable working solution.

How does Defender Ultra differ from Defender Ultra M?

Defender Ultra is a universal product for a wide range of operations, while Defender Ultra M is more suitable where specialization for non-ferrous metals is important.

Can Defender Ultra be mixed with other metalworking fluids?

This should not be done without checking compatibility. Mixing different products can lead to solution instability and system problems.

How do I select the correct Defender Ultra concentration?

The exact concentration depends on the operation, metal, water quality, and operating regime. Real application conditions must be considered for accurate selection