Performance and wear mechanisms of uncoated cemented carbide cutting tools in Ti6Al4V machining

The primary tool material when machining Ti6Al4V titanium alloy is uncoated straight cemented carbide. This study examines the performance of these materials during high-speed finish turning, and uses the advanced microscopy methods of SEM, (S)TEM, XEDS, and SAED to explore the fundamental tool wear mechanisms. The wear modes include a combination of flank wear and rake cratering. Four individual TEM lamellae were extracted from the crater and flank of one as-worn tool to investigate the wear mechanisms of cemented carbide exposed to different temperatures and contact conditions. The main wear mechanism identified is temperature-driven diffusion. Outward carbon diffusion occurs from surface WC grains into the adhered Ti alloy, which results in a layer of metallic tungsten. Dissolution of the W layer leads to doping of the α-Ti, thus causing its transformation into the β-Ti phase. At the same time, carbon-depleted WC grains interact with the Co binder, inducing formation of Co₃W. Additional wear mechanisms include inward titanium diffusion, resulting in formation of TiC on both sides of the W layer. Simultaneously, TiCo₂ is formed in Co-rich regions in the vicinity of the tool-chip interface. These reaction products retard direct dissolution of tool material in Ti6Al4V, thus acting as localized tool protection layers.