Spray forming

About: Spray forming is a research topic. Over the lifetime, 1153 publications have been published within this topic receiving 12869 citations. The topic is also known as: spray casting & spray deposition.

Influence of Zn content on microstructure and properties of spray-formed 7××× series aluminum alloys

Abstract: The ultra-high strength aluminum alloys with high Zn content were prepared by spray forming technology, and the microstructure and properties of alloys were studied. The results show that the as-deposited materials reveal a spheroid grain morphology with an average grain size of 1020 μm. XRD analysis results indicate that the as-deposited alloys consist of α(Al), MgZn_2, Al_2Cu and Al_2CuMg phases. The ultimate tensile strength of the alloy with 9.5%11.5% Zn content can get to 815 MPa after T6 heat treatment. Based on the microstructure and properties, the Zn content should be controlled between 9.5% and 11.5%.

Spray Forming Aluminum - Final Report (Phase II)

Abstract: The U.S. Department of Energy - Office of Industrial Technology (DOE) has an objective to increase energy efficient and enhance competitiveness of American metals industries. To support this objective, ALCOA Inc. entered into a cooperative program to develop spray forming technology for aluminum. This Phase II of the DOE Spray Forming Program would translate bench scale spray forming technology into a cost effective world class process for commercialization. Developments under DOE Cooperative Agreement No. DE-FC07-94ID13238 occurred during two time periods due to budgetary constraints; April 1994 through September 1996 and October 1997 and December 1998. During these periods, ALCOA Inc developed a linear spray forming nozzle and specific support processes capable of scale-up for commercial production of aluminum sheet alloy products. Emphasis was given to alloys 3003 and 6111, both being commercially significant alloys used in the automotive industry. The report reviews research performed in the following areas: Nozzel Development, Fabrication, Deposition, Metal Characterization, Computer Simulation and Economics. With the formation of a Holding Company, all intellectual property developed in Phases I and II of the Project have been documented under separate cover for licensing to domestic producers.

HIGH STRENGTH AND HIGH DUCTILITY Al ALLOY, AND METHOD FOR PRODUCING THE SAME

Abstract: PROBLEM TO BE SOLVED: To provide an Al-Zn-Cu 7000-series aluminum alloy which exhibits high ductility for its high strength. SOLUTION: The Al-Zn-Mg-Cu 7000-series aluminum alloy having an inclusion-free structure is produced by reducing the oxygen content of an Al alloy obtained by rapidly solidifying a molten Al-Zn-Mg-Cu 7000-series aluminum alloy into a preform with an inert gas, preferably by spray forming. The aluminum alloy of the invention has a tensile strength of 600 MPa or above as one of the mechanical characteristics at ordinary temperature and exhibits an elongation of 15% or above when the tensile strength is 600 MPa or above but below 800 MPa and an elongation of 10% or above when the tensile strength is 800 MPa or above, being excellent in cold workability such as rollability. COPYRIGHT: (C)2009,JPO&INPIT

Synthesis of bulk amorphous and nano-crystalline materials by spray forming

Abstract: Bulk amorphous and nanocrystalline metallic materials have been observed to possess excellent mechanical and physical properties. The conventional process routes to synthesize such materials are restricted by their ability to achieve rapid solidification which limits the dimensions of the materials produced. In the last ten years, spray forming has been used to avoid these limitations by using its layer by layer deposition of undercooled droplets. The available literature indicates that the opportunities provided by this process can be utilized to produce bulk materials in a single step. In the present paper, an attempt has been made to review the developments in the area of spray forming of amorphous and/or nanocrystalline materials. The effect of process parameters, droplet size distribution in the spray, the thermal conditions of droplets prior to deposition and the deposition surface conditions have been discussed in detail. It has been demonstrate that the layer by layer deposition of undercooled droplets of glass forming alloys on a relatively cold deposition surface is the suitable condition to achieve amorphization/nanocrystallization. A critical analysis of the process parameters and the results has been made based on the composition, glass forming ability and possible mechanisms of microstructural evolution.

Coating porosity simulation of plasma spray forming based on droplet multi-dimensional features

Abstract: The microstructure(such as pore size,shape,distribution,and surface roughness,etc)of the coatings manufactured by plasma spray forming affects their physical and mechanical properties,and thereby affects the product quality and performance To facilitate the study of spray forming process and the influence of spraying parameters on coating porosity,the microstructures of the plasma spray formed coatings are simulated based on the digital splat generated from the splat photo including its shape characteristics and multidimensional statistical characteristics such as time and space for consideration,and the nickel aluminum alloy is taken as an example The porosity of the simulated coating is 613%,which is similar to the experimental results 57% under the same conditions according to the references The results have referencial implications for the quality control of spray forming molds and parts