Additive manufacturing of graded B4C-Al cermets with complex shapes

Fabrication of boron carbide (B4C) parts through direct ink writing at room temperature has been demonstrated. The 3D printed B4C parts were made from aqueous, thixotropic ink consisting of B4C particles with a solid loading ranging from 50.0 to 59.3 vol%. The porous B4C parts were infiltrated with molten aluminum (Al) to form a dense B4C-Al cermet. Simple cubic samples with varied spacing between B4C filaments were printed to tailor the density profile within the part. The Rockwell hardness of such parts ranges from 20 to 90 Ra (60 kg) depending on the overall density of the B4C structure. Parts were printed with variable spacings between filaments to systematically determine the upper limit for Al infiltration (800 μm). Elemental analysis revealed a homogenous infiltration both between and within the filaments of 3D printed B4C.