Abstract
In the cylinder liner of a sleeveless engine, molten iron-based alloys are directly sprayed onto the aluminum engine block instead of the previously used cast iron cylinder liner. However, a thermal spraying cylinder liner exhibits poor machining performance during the finish boring process because of severe tool wear. This research investigates the finish boring performance of a thermal spraying cylinder liner to clarify the root cause of tool wear. The results show that abrasion is a dominant effect.