Fabrication of Silicon Carbide–Aluminum Composites Using Binder Jetting Additive Manufacturing Followed by Sintering Without Infiltration: A Preliminary Study

Silicon carbide–aluminum (SiC–Al) composites offer high hardness, wear resistance, thermal stability, and strength-to-weight ratio, making them suitable for advanced engineering applications. Fabricating these composites via powder metallurgy and infiltration methods has been reported. However, there is no reported study on fabricating SiC–Al composites using binder jetting additive manufacturing (BJAM) followed by sintering without infiltration. The present study aims to fill this gap. In this study, samples were printed by BJAM using SiC–Al mixed powders with two volumetric ratios (SiC:Al) of 60:40 and 80:20, respectively. These printed samples were then sintered at different temperatures (950 °C, 1200 °C, and 1400 °C). The results show that, using this new approach, the printed green samples retained structural integrity after sintering and that interparticle bonding was achieved. To the authors’ knowledge, this is the first study to fabricate a SiC–Al composite via binder jetting additive manufacturing using a mixed powder, followed by sintering without infiltration.