The ALBINA project investigated whether algae‑derived extracts could replace conventional mineral‑oil additives in metal machining and forming. Experiments were carried out on a 3‑axis CNC milling machine (VC 810, Spinner) equipped with a Kistler piezoelectric force plate and a pro‑micron tool holder (Spike V1.2). The workpiece material was tempered 42CrMo4 steel, hardened to 57 ± 2 HRC for drilling, reaming, and thread cutting, and to 45 ± 2 HRC for face milling. Key process parameters measured were axial, radial, and tangential forces, bending moment (Mx, My), torsion, tool run‑out, and surface roughness (Ra/Rz).

For full drilling, 65 holes were produced under three lubrication regimes: dry, 5 % KSS emulsion without performance additives, and unalloyed mineral oil (22 mm² s⁻¹ at 40 °C). The dry and mineral‑oil runs showed virtually identical bore diameters with negligible scatter. In contrast, the KSS emulsion produced a noticeable deviation from the target 6.8 mm diameter after the 21st hole, accompanied by a wide spread of values. Force measurements confirmed that the KSS emulsion induced higher cutting forces than both dry and mineral‑oil conditions, leading the team to exclude drilling from further additive‑performance studies.

Thread cutting of 31 threads under the same 5 % KSS emulsion revealed no significant increase in torsional load or tool wear, indicating that thread cutting was also unsuitable for evaluating additive performance.

Face milling of circular pockets was chosen as the most promising test. A counter‑rotating milling strategy on a high‑speed RXP 601 DS machine was used, with 5 % KSS emulsion as the base fluid. Conventional additives TPS20 and TPS32 (0.05 % each) and an EPS extract from the microalga Dixoniella grisea (0.005 % and 0.05 %) were added. The algae extract contains roughly 25 % functionalised polysaccharides, 34 % proteins, 28 % fatty acids, and some oxime structures. In high‑speed cutting of 42CrMo4, the algae extract performed on par with the conventional additives. In high‑speed cutting of TiAl6V4, the algae extract outperformed the conventional additives, reducing cutting forces and improving tool life. In metal‑forming tests—deep drawing of AlMg3 cups and internal thread forming—the algae extract also showed positive tribological effects, though less pronounced due to limited solubility in the base oil.

The project was organised in nine work packages. AP 0 (preparatory work) and AP 1 (literature review) were led by the University of Bremen (P1) and the University of Wismar (P4). AP 7 carried out the technical‑scale performance tests, while AP 8 coordinated the overall project and AP 9 handled reporting and dissemination. Partners P2, P3, P5, and the associated partner P7 contributed to chemical, microbiological, and mechanical testing. The study was conducted over a multi‑year period, with regular industry‑work‑group meetings to assess progress and plan future work. Although the funding source is not explicitly stated, the structure and scope suggest support from a national research programme or an EU Horizon grant. The results demonstrate that algae‑based additives can match or exceed conventional mineral‑oil additives in high‑speed machining of titanium alloys and offer a viable, environmentally friendly alternative for metal‑forming processes.