This paper explores the additive manufacturing of nickel-titanium (Ni-Ti) shape memory alloys (SMAs) using binder jetting and subsequent solid-state sintering under an Ar atmosphere. The consolidated 3D-printed Ni-Ti parts exhibit a correlation between pore morphology, pore fraction, and phase formation at different solid-state sintering temperatures. At a sintering temperature of 1175 °C, NiTi grains with TiC precipitates along grain boundaries are observed, accompanied by irregular, interconnected pores constituting ∼15 % of the volume. Increasing the sintering temperature to 1185 °C leads to the formation of a minor phase of Ni4Ti3 within NiTi grains, along with grain boundary TiC precipitates, and isolated pores with a volume fraction of ∼5 %. The higher sintering temperature corresponds to a higher average nanohardness value (8.1 GPa or 763 Hv compared to 6.9 GPa or 654 Hv), indicating the presence of a greater abundance of secondary phases and higher densification at the elevated sintering temperature. While the transformation temperatures (TTs) were undetectable in the bulk-printed samples, a different structure featuring designed channels and thin struts, sintered under similar conditions, exhibited detectable TTs, with a martensite start temperature of 34 °C. Biocompatibility tests demonstrated cell spreading and attachment on both sintered Ni-Ti samples. These findings offer valuable insights into the potential use of binder jetted Ni-Ti for medical implants and tissue engineering applications.
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