Abstract
Spray forming involves sequential gas atomization of a melt into a spray of fine droplets and their deposition on a substrate to build up a high-density preform. The rapid solidification inherent in spray deposition generates refined, equiaxed and low segregation microstructures. A number of promising features of this near-net shape manufacturing process are highlighted and compared, wherever possible, with the conventional casting and PM techniques. Some commercial nozzles used to create spray and mechanisms associated with spray generation are described. The consolidation of the droplets and the development of the microstructure in the deposit are primarily governed by the nature of the spray and the thermal state of droplets on the deposition surface. Several microstructural characteristics of the deposit are presented and their origin in spray deposition is discussed.
This is a preview of subscription content, log in via an institution to check access.
Similar content being viewed by others
References
Anantharaman T R and Suryanarayana C 1971J. Mater. Sci. 6 1111
Ando T, Lavernia E J and Grant N J 1986Mater. Letts. 5 17
Beddow J K 1978 inThe production of metal powders, (London: Hyden & Sons)
Bewley B P and Cantor B 1990Met. Trans. B21 899
Bewley B P and Cantor B 1991J. Mater. Res. 6 1433
Bricknell R H 1986Met. Trans. A17 583
Brooks R G, Leatham A G, Coombs J S and Moore C 1977aMetall. Met. Form. 9 1
Brooks R G, Moore C, Leatham A G and Coombs J S 1977bPowder Met. 2 100
Chen H S and Miller C E 1970Rev. Sci. Instrum. 41 1237
Clyne T W, Ricks R A and Goodthew P J 1984Int. J. Rapid Solidification 1 59
Duszczyk J and Estrada J L 1990J. Mater. Sci. 25 1381
Gordon G D 1959J. Appl. Phys. 30 1759
Grant N J 1978 inRapid solidification processing: principle and technology, (eds) R Mehrabian, B H Kear and M Cohen (Baton Rouge: Claitor’s Pub. Div.) p. 230
Guitierrez E, Lavernia E J, Trapaga G, Izekely J and Grant N J 1989Met. Trans. 20 71
Ikawa Y 1990ISIJ Int. 30 756
Jones H 1973Rep. Progr. Phys. 36 1425
Jones H 1986Proc. Structural metals by rapid solidification, (eds) F H Froes and S J Savage (Orlando: ASM International) p. 77
Kim M H and Jones H 1981Rapidly quenched metals IV, (eds) T Masumoto and K Suzuki (Sendai: The Japan Institute of Metals) p. 85
Klar E and Fesko J W 1984Metals Handbook, (Metals Park, OH: ASM) Vol. 7, p. 25
Kurten J 1978 inBubbles, drops and particles, (New York: Academic Press)
Lane W R 1951Indian Engg. Chem. 43 1312
Lavernia E J 1989Int. J. Rapid Solidification 5 47
Lavernia E J and Grant N J 1986Mat. Powder Rep. 4 255
Lavernia E J and Grant N J 1988Mat. Sci. Engg. 98 381
Lawley A 1986J. Metals 38 15
Lawley A, Mathur P, Apelian D and Meystel A 1990Powder Met. 33 109
Leatham A F, Elias L and Ogilvy A 1991Met. Powder Rep. 46 38
Lubanska H 1970J. Metals 22 45
Magusar J, Lavernia E J, Domalavage P, Harling O K and Grant N J 1984J. Nucl. Mater. 122–123 789
Mathur P, Annavarapu S, Apelian D and Lawley A 1991Mater. Sci. Engg. A142 261
Mathur P, Apelian D and Lawley A 1989Acta Met. 37 429
Ojha S N, Jha J N and Singh S N 1991Scr. Met. Mater. 25 443
Ojha S N, Pandey O P, Tripathi B, Kumar M and Ramachandra C 1992Mater. Trans. JIM (in press)
Ojha S N and Satyanarayana K G 1992 (unpublished work)
Ojha S N and Singh S N 1991J. Mater. Sci. Letts. 10 893
Pandey O P and Ojha S N 1991Powder Met. Int. 23 291
Ranz W E and Marshall W R 1952Chem. Engg. Prog. 48 173
Rickinson B A, Kirk F A and Davies D R G 1981Powder Met. 1 1
Ricks R A, Adkins N J E and Cyne T W 1986Powder Met. 29 27
Savage S J and Froes F H 1984J. Metals 36 20
See J B and Johnston G H 1978Powder Tech. 21 118
Singer A R E 1970Met. Mater. 4 246
Singer A R E 1972J. Inst. Met. 100 185
Singer A R E and Evans R W 1983Met. Technol. 10 61
Singh S N 1991Development and analysis of an atomization process for spray deposition, Ph. D. thesis, Banaras Hindu University, Varanasi
Singh S N and Ojha S N 1991Metals, Materials & Processes 3 53
Singh S N, Mishra N S and Ojha S N 1992Steel Res. 63 12
Szekely J 1979Fluid flow in metals processing, (New York: Academic Press) p. 261
Taylor G I 1950Proc. R. Soc. A201 192
Unal A 1987Mater. Sci. Technol. 3 1029
Unal A 1989Met. Trans. B20 61
Williams B 1980Met. Powder Rep. 10 464
Wolf H E and Anderson W H 1965Proc. 5th Int. Shock tube symposium, p. 1153
Author information
Authors and Affiliations
Rights and permissions
About this article
Cite this article
Ojha, S.N. Spray forming: Science and technology. Bull. Mater. Sci. 15, 527–542 (1992). https://doi.org/10.1007/BF02747543
Issue Date:
DOI: https://doi.org/10.1007/BF02747543