Abstract:Binder jetting is a potential low-cost method to near-net-shape fabricate 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 for ensuring the large-scale application of binder jetting. In this study, a series of W-Ni-Fe alloy billets were fabricated with variables including powder particle size, binder material, binder saturation, and single-layer printing thickness. The compressive strength of the billets was tested, as well as the influence of material characteristics and process parameters on the quality of W-Ni-Fe billets was analyzed. The results indicate that the compressive strength of binder-jetted W-Ni-Fe alloy billets exhibits a negative correlation with powder particle size and single-layer printing thickness, while increasing continuously with higher binder saturation. By employing a water-based alcohol binder, the W-Ni-Fe powders with a D50 particle size of 7.62 μm, a binder saturation of 70%, and a single-layer printing thickness of 60 μm, the binder-jetted W-Ni-Fe alloy billets achieve a balance between good strength and dimensional accuracy.