I'd like to learn more about this process, having just recently broken a 4-40 tap in a cast iron mini-mill base. Fortunately, the power feed safety stop switch I was mounting could be relocated. Why doesn't the Alum also dissolve the surrounding material holding the broken bit or tap? What kinds of metals will Alum dissolve or not dissolve? I've never seen what happened to that tap happen before. It was a spiral flute tap (it's all I use once I discovered them!) and it was going in fairly easily with lubricant, held straight with a tap guide block. After several turns I decided to back out and clean out the tap so I could proceed deeper. When I tried to turn it in reverse, it bound up, and while very gently twisting it back and forth to try to free it up it snapped off. First one I can remember breaking during removal. I'm thinking the casting may have had some impurities in that spot.