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.

Production, microstructural and mechanical characterization of spray formed Al-6 wt.% Fe alloy and pre-mixed Al-6 wt.% Fe/SiCp composite

Abstract: Different batches of Al–6 wt% Fe and of pre-composite Al–6 wt% Fe/SiC powders were produced, via melting of aluminum followed by iron addition in the induction furnace of a gas atomizing unit, eventually adding in situ a suitable amount of SiC particulate The inclusion of the reinforcing particles in the melt was enhanced by means of stirring under an argon shielding atmosphere Gas atomization via sonic close-coupled discrete jet nozzles was thereafter performed, and a part of the spray cone was intercepted by a still substrate The microstructural characterization of both the pre-composite powder and of the spray deposited samples was carried out by microscopy, image analysis and X-ray diffraction The high viscosity of the matrix allowed to achieve a maximum volumetric fraction of reinforcement of around 10% By means of X-ray stress analysis the residual stresses in the spray formed specimens were determined, and resulted to be compressive, and higher in the composite material The elastic properties of the spray formed samples were determined by the flexural resonance test, carried out on prismatic samples cut from the spray formed samples, while their transverse strengths were determined by three points bend test

Potentiodynamic Polarization Aspects of the As-cast and Sprayed Al-Si, Al-Sn and Al-Sn-Si Alloys in a Sodium Chloride Solution

Abstract: The present study compares the corrosion behavior of Al-Sn, Al-Si and Al-Sn-Si alloys processed by spray forming with that of the conventional chill cast ones in aqueous 0.1 N NaCl solution. Spray forming resulted in finer microstructural features with uniform distribution of second-phase particles. The spray formed Al-Si samples showed improved corrosion resistance as compared to the chill cast ones. The Sn containing alloys showed inferior corrosion resistance in the neutral electrolyte. The addition of 12.5 wt.% Si to Al-Sn alloys improves the corrosion resistance.

A plasma spray process for the manufacture of long-fiber reinforced Ti-6Al-4V composite monotapes

Abstract: A fabrication method for titanium matrix composite monotapes reinforced by long SiC fibers is described. The plasma spray technique, carried out in an inert atmosphere, was used to deposit the metal matrix onto previously arranged continuous fibers.

Investigation on metallurgical, tribological, hardness properties of spray deposited and warm rolled Al-18Pb, Al-22Pb alloys

Abstract: Al-18Pb and Al-22Pb alloys were processed by a rapid solidification process known as the spray deposition technique. Gaussian or bell-shaped deposits were obtained at a pressure of 10 bar, nozzle to substrate distance of 423 mm and substrate inclination angle of 0°. Deposits obtained from both alloys were warm rolled at a recrystallization temperature of 395 °C. Microstructural analysis of deposits showed that Pb is equally distributed in the Al matrix with 60% thickness reduction. For both alloys, the decrease in thickness percentage resulted in the decrease of hardness values. Porosity was lower in spray deposits of Al-18Pb alloy than the corresponding one from Al-22Pb alloy due to the casting and rolling defects. When the Pb percentage is increased from 18 to 22 in Al-22Pb compared with Al-18Pb, the wear rate increases abnormally. The frequency of wear and coefficient of friction values of Al-22Pb alloy were also higher when compared with those of Al-18Pb alloy.

Manufacturing clad products by spray forming

Abstract: Whilst it has been feasible to spray form clad products for several years, it has been difficult to generate a high integrity metallurgical bond at the interface of the mandrel and the sprayed alloy. Consequently, roll preforms have generally been produced in the form of rings which are subsequently fitted to the roll arbor or mandrel. However, a joint project in progress between Forged Rolls (UK) Ltd, British Rollmakers Corporation, Osprey Metals Ltd and Sheffield University (with part funding from the UK, Department of Trade and Industry, under the LINK enhanced engineering materials programme) has demonstrated that direct bonding of roll alloys onto steel arbors can be achieved using arbor preheating in conjunction with multi-atomisers and other special techniques. The equipment to achieve such results is described, together with an outline of the deposition method. Initial metallographic and mechanical property results are also presented with a comparison made between conventionally processed and spray formed roll alloys, where a considerable refinement in the spray formed microstructure is apparent. These encouraging results have led to the spray forming of narrow, clad hot and cold strip mill rolls for actual field trials.