While powder metallurgy typically employs net-shape processing to produce parts, it is not uncommon for machining of features, such as undercuts, grooves and chamfers, to be included as a secondary operation process step. Machining of sintered ferrous alloys is assisted by additions of machining aids, such as MnS, however, due to titaniums reactivity, this is not an option for titanium alloys. Furthermore, titanium alloys are notoriously difficult to machine due to their combination of superior properties which results in accelerated tool wear and limited tool life.
In this study, sintered Ti6Al4V samples are produced over a range of densities, yielding samples with differing residual porosity. The influence of residual porosity on the mechanical properties and thermal conductivity of the sintered material is linked to tool wear during face turning machining tests. The results show that there is a delicate interplay between properties, that influences tool wear.