10/24 roll form taping in steel

How deep is the cut? Are you using a slow sprial tap? If so, you may want to try a fast sprial tap to remove the chips faster and maybe you'll get less wear..

The drill diameter is OK in fact slightly on higher side (recommended for 10-24 is 0.170-0.174). Do you check the holes (tapped) with Thread gauge ?

When the dia is getting enlarged is thread as per gauge still OK ?

I suspect the major dia (the forming edge) is wearing out and that is not generating enough metal flow.

Check the suitability of material with ref to the forming (may be high tensile/ hard material ? ) that case anyway you are likely to have less tap life.

Since in this small size, you can not experiment with through the tool cooling , try to experiment with coolant. Did you try cutting oil ? it may help in better conductivity of the generated heat and the higher viscosity may improve the lubrication.

Your best bet is to directly contact the tap manufacturer for advice. They may have a different tap design or coating more compatible with your specific requirements.

Bottoming taps are made just for that bottoming. They are not designed to tap a complete hole from top to bottom, they are made to get the last few turns at the bottom of the hole.You need a gun tap to go as far as you can then use the bottoming tap preferrably after the hole has been cleaned out.You could also try a roll forming tap as there will be no chips to worry about.