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Spray forming
Spray forming, also known as spray casting, spray deposition〔.〕 and in-situ compaction,〔.〕 is a method of casting near net shape metal components with homogeneous microstructures via the deposition of semi-solid sprayed droplets onto a shaped substrate. In spray forming an alloy is melted, normally in an induction furnace, then the molten metal is slowly poured through a conical tundish into a small-bore ceramic nozzle. The molten metal exits the furnace as a thin free-falling stream and is broken up into droplets by an annular array of gas jets, and these droplets then proceed downwards, accelerated by the gas jets to impact onto a substrate. The process is arranged such that the droplets strike the substrate whilst in the semi-solid condition, this provides sufficient liquid fraction to 'stick' the solid fraction together. Deposition continues, gradually building up a spray formed billet of metal on the substrate.
The ''gas atomised spray forming'' (''GASF'') process typically has a molten alloy flow rate of 1–20 kg/min-1, although twin atomizer systems can achieve metal flow rates of up to 80 kg/min. Special steel billets of 1 tonne or more have been produced by spray forming on a commercial basis, together with Ni super-alloy ring blanks of up to 500 kg and Al alloy extrusion billets of up to 400 kg.
==History==
Professor Singer at the Swansea University first developed the idea of gas atomised spray forming in the 1970s in which a high pressure gas jet impinges on a stable melt stream to cause atomisation. The resulting droplets are then collected on a target, which can be manipulated within the spray and used to form a near-dense billet of near-net shape. Spray forming has found applications in specialist industries such as: stainless steel cladding of incinerator tubes; nickel superalloy discs and rings for aerospace-engines; aluminium-titanium, aluminium-neodymium and aluminium-silver sputter targets; aluminium-silicon alloys for cylinder liners; and high speed steels. The history of spray forming of how spray forming then developed is an example of how the creative contributions of many researchers were necessary over a number of years to produce the innovation of a now widely used industrial process.
抄文引用元・出典: フリー百科事典『 ウィキペディア（Wikipedia）』
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