In situ formation of metal matrix composites using binder jet additive manufacturing (3D printing)

Simplifying the manufacturing of metal matrix composites (MMCs) will allow for their wider use in applications that require lower density, higher strength, and high wear resistance when compared to traditional metals. An in-situ method of MMC formation is proposed, using a binder jet additive manufacturing (BJ-AM) process with only Inconel 625 powder and a carbon-containing binder. Carbide formation occurs at elevated temperatures during sintering by combining Cr, Mo and Nb alloying elements in Inconel 625 and carbon from the binder. The core-shell morphology and composition of the final MMC is tuned by controlling the quantity of carbon in the system during the sintering step.