Diffusion related wear mechanisms of WC/Co carbide tools in conventional and laser-assisted machining of γ-TiAl intermetallic alloys

The γ-TiAl alloys are ideal materials for key components of aeroengines, and tool wear is a key factor limiting the quality and efficiency of its manufacturing. In this study, tool wear mechanisms of both conventional and laser-assisted machining of γ-TiAl intermetallic alloys were investigated. Experimental and numerical analyses reveal that high-temperature promotes element diffusion between γ-TiAl and WC/Co carbide tools. Carbon diffuses outward from WC grains, forming TiC on the surface, while carbon-depleted WC decomposes into WO₃. Rising temperatures accelerate adhesion, diffusion, oxidation, and abrasion, reducing tool strength by up to 85 %. The high chemical activity of Ti element further aggravates adhesive wear. This paper reveals the nature of wear behaviors induced by diffusion during machining of γ-TiAl alloy.