Will this work well with aluminum milling without staining and prevent rust on my milling machine?

Yes it works well on alum. I have not had any rust problem.

what is the ratio of coolant to water recommended?

For KOOLMIST #77 OR #78A mix of a maximum of 32:1 with water. Depending on the metal that is being cut ... for the best lubricity ... utilize 20 to 25:1 ... history shows the best performance at these numbers.

can you use this just with a nozzle without misting?

It’s formulated for misting because it’s concentrated. You could do it manually or with a spray bottle if you wanted. Your mileage may vary.

Can it be used with recirculating systems ?

when diluted as directed I would think it would recirculate easily, but being mostly water it will rust steel components - I found out the hard way. I mounted a spray system on mil bridgeport and I'm going to switch to wd40 coolant. hope this helps you

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Kool Mist #77 Concentrated Coolant - Container Size: 1 Gallon Series: #77

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