Abstract:Binder jetting is a potential low-cost near-net-shape forming method for large-scale complex-shaped W-Ni-Fe alloy components. Nonetheless, it faces challenges such as billets cracking during curing and debinding. Developing the manufacturing process for high-strength W-Ni-Fe alloy billets is an inevitable requirement. In this study, a series of 93W-4.9Ni-2.1Fe alloy billets were prepared by binder jetting with variables including powder particle size, binder material, binder saturation, and single-layer printing thickness. The compressive strength of the billets was tested, and the effects of material characteristics and process parameters on the quality of 93W-4.9Ni-2.1Fe billets was analyzed. The results show that the compressive strength of binder-jetted 93W-4.9Ni-2.1Fe alloy billets exhibits a negative correlation with powder particle size and single-layer printing thickness, which improves continuously with the increase in higher binder saturation. By employing a water-based alcohol binder, the 93W-4.9Ni-2.1Fe powders with a D50 particle size of 7.65 μm, a binder saturation of 70%, and a single-layer printing thickness of 60 μm, the binder-jetted 93W-4.9Ni-2.1Fe alloy billets achieve a balance between good strength and dimensional accuracy.