Work

Effects of binder saturation and sintering temperature on the microstructure and properties of binder jet additively manufactured Ti–6Al–4V

Year: 2026

Type: article

Abstract: : This study establishes an end-to-end process–defect–microstructure–property linkage to optimize water-based binder jetting of Ti-6Al-4V. Spherical Ti-6Al-4V powder with a particle size of 15–53 μm and a water-based PVP binder was used to print green bodies at binder saturations of 50%, 60%, and 70%. Integrated characterization and mechanical testing validated a competing cratering–tunneling mechanism. Low binder saturation causes droplet-impact defects and weak interlayer bonding, whereas high saturation accelerates binder infiltration and particle agglomeration. Increasing saturation raises the green compressive strength to 1.70 MPa but leads to large pores that persist after sintering. An effective peak debinding temperature of 500 °C was identified. The residual carbon and oxygen contents in the sintered specimens are 0.118–0.153 wt% and 0.327–0.383 wt%, respectively. Within the 1300–1450 °C sintering window, higher temperature promotes densification, but oxygen absorption and lamellar α coarsening degrade ductility. The optimal processing window is 60% binder saturation with sintering at 1350 °C, which yields the best overall mechanical properties. Unlike conventional single-parameter optimization studies, this work closes the causal loop across the additive manufacturing process and provides a theoretical basis for defect control and performance improvement in components produced by water-based binder jetting of Ti-6Al-4V.

Source: Journal of Materials Research and Technology

DOI: 10.1016/j.jmrt.2026.08.074