Metal Binder Jetting (MBJ) 3D printing is an attractive additive manufacturing (AM) method for high volume production of metals and ceramics. However, the widespread use of MBJ has been stymied by longstanding challenges in reduced strength properties compared with traditional wrought and laser-based AM materials. In this study, we leveraged novel “drop-on-demand” Metal Material Jetting (MMJ) of sub-micron powders to fabricate SS316L samples. These samples were subjected to dilatometry, mechanical testing, and correlative materials characterization and compared to metal binder jet (MBJ) SS316L to evaluate differences in process-structure-property relationships between the two processes. Overall, MMJ SS316L possessed an average tensile yield and ultimate tensile strength of 312 ± 84 MPa and 640 ± 38 MPa respectively, greatly exceeding MBJ SS316L in the literature due to the formation of fine microstructures with an average grain size of 2.4μm. Importantly this led to significant Hall-Petch strengthening but also considerably lower average failure strains (15.5 ± 4.8 %). The process-microstructure-property relationships facilitating microstructural evolution in MMJ are discussed and further elucidated using an isotropic pressure-less viscous sintering model. Results of this model show that, although densification behaviors in MMJ were largely similar to those in MBJ, MMJ samples possessed over three-fold increase in sintering stress, defined the change in free surface energy with respect to the volumetric shrinkage, and ∼31 % reduction in grain growth due to the employment of sub-micron size powders. Overall, these results show the promise of MMJ AM for structural metals and suggest that both microstructure (and ultimately strength) of MMJ materials can be further tuned by controlling the overall sintering process.
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