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Cracking during sintering is a common problem in powder processing and is usually caused by constraint that prevents the sintering material from shrinking in one or more directions. Different factors influence sintering‐induced cracking, including temperature schedule, packing density, and specimen geometry. Here we use the discrete element method to directly observe the stress distribution and sinter‐cracking behavior in edge notched panels sintered under a uniaxial restraint. This geometry allows an easy comparison with traditional fracture mechanics parameters, facilitating analysis of sinter‐cracking behavior. We find that cracking caused by self‐stress during sintering resembles the growth of creep cracks in fully dense materials. By deriving the constrained densification rate from the appropriate constitutive equations, we discover that linear shrinkage transverse to the loading axis is accelerated by a contribution from the effective Poisson's ratio of a sintering solid. Simulation of different notch geometries and initial relative densities reveals conditions that favor densification and minimize crack growth, alluding to design methods for avoiding cracking in actual sintering processes. We combine the far‐field stress and crack length to compute the net section stress, finding that it characterizes the stress profile between the notches and correlates with the sinter‐crack growth rate, demonstrating its potential to quantitatively describe sinter‐cracking.

 

Binder jet three-dimensional (3D) printing is a scalable, potentially low-cost additive manufacturing route able to process materials not attainable to other techniques, especially nonweldable materials. It relies on postprocess sintering to achieve final properties but encounters problems with distortion and cracking during sintering. The present work seeks to understand how part design geometry and 3D printing build orientation influence cracking during sintering, with the goal of mitigating the problem. In situ monitoring experiments reveal how sinter-cracks initiate and grow in 3D-printed notched panel specimens during densification. Different design geometries and build directions are tested to identify sinter-crack-resistant regimes.