Spray forming technology

The main attraction of spray forming is the single step required to change a molten alloy into a consolidated product. Semi-finished product shapes fabricated by spraying gas-atomized molten metal droplets onto a substrate are free from micro-segregation, are low in oxygen content, and exhibit enhanced hot workability. Other process benefits include low capital costs (less equipment required); low operating costs (low energy consumption and high material yields); and low overhead costs (less stock and work-in-progress, with shorter delivery). In spite of these benefits, significant advances in the spray forming process are necessary in order to compete in the commercial marketplace against high-volume, established ingot metallurgy processes involving ingot casting, forging, and/or rolling. Toward this end, much progress has recently been made.