Fabrication of SiC-Al composites using binder jetting 3D printing and infiltration: effects of printed sample density on infiltration

IF 2.8 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters Pub Date : 2026-10-01 Epub Date: 2026-10-05 DOI:10.1016/j.mfglet.2026.07.099

Jackson Sanders, Evgenia Dimitriou, Zhijian Pei, Edoardo Ghinatti, Fahim Khan, Stephen Kachur

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Abstract

This study examines how powder bed compaction during binder jetting 3D printing of silicon carbide (SiC) samples influences SiC sample density and affects subsequent aluminum-magnesium (Al+Mg) infiltration of the printed SiC samples. SiC samples were printed with and without compaction, then cured, depowdered, sintered at 1600 °C, and infiltrated with Al+Mg to produce composite samples. Green samples (printed samples after curing and depowdering) were evaluated for density, sintered samples for density and porosity, and infiltrated samples for density, porosity, infiltration uniformity, penetration depth, and morphology. Results show that the density of green samples printed with powder bed compaction was 6.79% higher than that of green samples printed without compaction; however, this advantage was largely diminished after sintering, resulting in similar final density (≈2.53 g/cm³) and porosity (≈36%) for both groups of samples. However, infiltration behavior of these two groups of samples differed substantially: the samples printed with compaction exhibited greater infiltration area and deeper penetration than the samples printed without compaction. Quantitative image processing analysis revealed that the sample printed with compaction exhibited greater percentage of infiltration area as well as deeper infiltration penetration across measured edges compared with the sample printed without compaction.

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粘结剂喷射3D打印制备SiC-Al复合材料及渗透：打印样品密度对渗透的影响

本研究考察了粘结剂喷射3D打印碳化硅（SiC）样品过程中的粉末床压实如何影响SiC样品密度，并影响随后打印的SiC样品的铝镁（Al+Mg）渗透。对SiC样品进行压实和不压实的打印，然后在1600℃下固化、脱粉、烧结，再用Al+Mg浸渍制备复合材料样品。绿色样品（固化和脱粉后的打印样品）的密度评估，烧结样品的密度和孔隙度评估，渗透样品的密度、孔隙度、渗透均匀性、渗透深度和形貌评估。结果表明：经粉床压实处理的绿色样品密度比未压实处理的绿色样品密度高6.79%；然而，这一优势在烧结后大大减弱，导致两组样品的最终密度（≈2.53 g/cm3）和孔隙率（≈36%）相似。然而，两组样品的渗透行为有很大的不同：压实打印的样品比未压实打印的样品具有更大的渗透面积和更深的渗透。定量图像处理分析表明，与未压实打印的样品相比，压实打印的样品具有更大的渗透面积百分比以及更深的渗透穿过测量边缘。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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