I'm sure others have broken taps... I broke one off flush with the surface in a blind hole in aluminum. Anyone ever get these out again?
Ways of removing it include
-Welding a nut on it
-Drilling out with a left handed kobolt or carbide drill bit
-drilling out then using tap extractor
-Dissolving the tap with nitric acid (Tap X only works with aluminum or other non ferrous metals)
-Drilling out with normal carbide drill bit and picking away remnants
-Die sinker EDM or tap burner (like EDM but just meant for taps)
-Using grinder or dremel to put a slot into it
My favorite method usually is trying to drill it out, getting mad, crying, and then machining the part again....