Abstract:This work investigated the forming process optimization, microstructure and properties of the GH4099 alloy fabricated by binder jetting 3D printing (BJ3DP) to meet the needs of forming accuracy and service performance of complex components. The effects of layer thickness, binder saturation, roller traverse speed and drying time on the surface quality of green samples were analyzed through orthogonal experiments. The results reveal that binder saturation is the main control factor. The optimized parameters significantly improve the forming uniformity and dimensional stability. In addition, the influence of sintering temperature on microstructure and properties was also investigated. It is found that when the sintering temperature is 1345 ℃, the relative density of the sample reaches 98.4%, and a large amount of coherent L12-Ni3(Al,Ti) phase are precipitated in this sample. Under this condition, the optimum mechanical properties are obtained, i. e., tensile strength of 669 MPa and yield strength of 590 MPa. The work establishes the mechanism of the synergistic regulation of GH4099 microstructure-property by printing and sintering parameters of BJ3DP, providing new ideas and theoretical support for achieving high-performance complex components of nickel-based alloys.