This study investigates how the microstructure of NiTi alloy affects tool wear during machining, comparing conventionally (W) and additively (LPBF) manufactured samples. Despite similar cutting forces, LPBF NiTi shows faster and more consistent tool wear, especially at low speeds, due to abrasive and adhesive mechanisms. Higher speeds reduce adhesive wear by shortening contact time. LPBF NiTi’s coarser, inhomogeneous microstructure contrasts with W NiTi’s finer one. DSC analysis shows W NiTi has a more stable austenitic phase, while LPBF NiTi is more ductile. Superelasticity (SE) is better retained in W NiTi post-machining, while LPBF shows SE loss, partially recovered with wear. Machining shifts Af higher in LPBF, affecting SE more. Both materials show SPD layers, thicker in W NiTi with wear. Surface roughness rises with wear, but LPBF surfaces remain smoother due to lower SE. Fresh tools improve surface finish more on LPBF, while higher speeds increase roughness despite low wear.
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