Predicting Chemical Wear in Machining Titanium Alloys Via a Novel Low Cost Diffusion Couple Method

Chemical wear during high speed machining of titanium alloys is a serious problem which affects the surface integrity of both the tool and workpiece. A low cost, novel diffusion couple method is presented which allows for thorough analysis of the tool-workpiece interface at the high temperatures reached during conventional machining operations. X-EDS analysis reveals that no less than seven distinct diffusion zones arise between Ti-6Al-4 V and a WC-Co tool which are home to different phases and reaction species. Loss of cobalt binder coupled with a deficit of carbon results in a brittle η-phase leading to catastrophic fracturing of the tool. DICTRA is employed to thermodynamically model the diffusion mechanisms and verify the X-EDS results.