Fabrication of SiC/Al-Mg Composites via Binder Jetting 3D Printing and Infiltration: Effects of Mg Content and Infiltration Temperature

This study systematically investigates the effects of infiltration temperature (800 and 1000 °C) and magnesium (Mg) content (0, 5, and 10 wt.%) on the density, morphology, and chemical composition of silicon carbide/aluminum-magnesium (SiC/Al–Mg) composites. Poor wettability between molten Al and SiC can restrict the infiltration of porous SiC preforms. Although Mg is commonly used to improve wettability, the combined effects of Mg content and infiltration temperature have not been investigated for composites produced from binder-jetted SiC preforms. Porous SiC preforms were first fabricated by binder jetting of SiC powder and then air-assisted oxidation bonded at 1200 °C for 2 h. The oxidation-bonded preforms were subsequently spontaneously melt infiltrated under an inert atmosphere using either pure Al powder or Al–Mg powder mixtures containing 5 or 10 wt.% Mg. The results showed that composite density increased consistently with increasing Mg content. At 800 °C, the density increased from 1.73 to 2.63 g/cm3 as Mg content increased from 0 to 10 wt.%. Similarly, at 1000 °C, the density increased from 1.80 to 2.73 g/cm3. X-ray diffraction, scanning electron microscopy, and energy-dispersive X-ray spectroscopy were used to evaluate phase formation and microstructural features. The results confirmed effective infiltration in Mg-containing samples, while samples without Mg showed limited infiltration at both temperatures. A two-way ANOVA showed that Mg content was the primary factor controlling post-infiltration density, while infiltration temperature had a smaller but statistically significant effect. These findings provide practical guidance for selecting Mg content and infiltration temperature during the fabrication of binder-jetted SiC/Al–Mg composites. Overall, this study highlights the importance of Mg-assisted infiltration for fabricating binder-jetted SiC/Al–Mg composites and provides processing insights relevant to their potential use in aerospace, automotive, and defense applications, subject to further evaluation of their mechanical and functional properties.