Spray casting of eutectic ferrous alloys, an alternative to powder metallurgy

The technique of atomising liquid metal and compacting the spray to the deposit on a moving substrate combines advantages from cast, wrought and powder metallurgical materials. A production rate of several tons per hour requires precisely controlled processing. Parameters based on physical, metallurgical and technological knowledge have been determined by fundamental investigations in a special research program (SFB 372) of DFG (Deutsche Forschungsgemeinschaft). Because of the advantage of near net shape production as due to casting, this process avoids partially machining which leads to a reduction in production costs. Research on high carbon steel and cast alloys was done to study the applicability of this low cost spray cast technology instead of expensive powder metallurgy production. (C) 2003 Maney Publishing.