Controlled process for the production of a spray of atomized metal droplets

Apparatus for producing an article having a uniform microstructure and a uniform macrostructure by incremental buildup of a metal by deposition of droplets of a metal spray formed from a molten metal stream, onto a substrate, comprising:

• (a.) a vessel having water-cooled walls for containing molten metal, the vessel further including a nozzle for discharging a stream of molten metal from the vessel;
• (b.) means for forming a metal spray from the stream of molten metal having an inlet for receiving the molten metal stream and an outlet for discharging a metal spray, said means positioned below the nozzle;
• (c.) a source sensor positioned above the vessel which detects a temperature of the molten metal in the vessel and transmits a signal indicative of the temperature;
• (d.) a source sensor positioned above the vessel which detects a level of the molten metal in the vessel and transmits a signal indicative of the level;
• (e.) a stream temperature sensor positioned in proximity to the molten metal stream which detects the temperature of the stream before the stream enters the spray-forming means and transmits a signal indicative of the stream temperature;
• (f.) a stream diameter sensor positioned in proximity to the molten metal stream which detects the stream diameter as it exits from the nozzle and transmits a signal indicative of the diameter size;
• (g.) a mounting apparatus for positioning the substrate relative to the metal spray;
• (h.) at least one mounting apparatus positioning sensor for indicating the position of the substrate within the mounting apparatus and which transmits a signal indicative of the substrate position;
• (i.) at least one spray forming means sensor which indicates the position of the spray outlet and transmits a signal indicative of the spray outlet position;
• (j.) a controller capable of receiving and transmitting signals, which determines appropriate stream diameter, stream temperature, molten metal level in the vessel, molten metal temperature in the vessel, spray direction and substrate position, and which receives sensor signals and transmits signals in response to the received signals;
• (k.) a heat source positioned above the vessel, capable of receiving a signal, for adjusting the molten metal temperature in the vessel in response to the signal transmitted by the controller;
• (l.) means for moving the spray forming means, capable of receiving a signal, for changing the direction of the spray in response to the signal transmitted by the controller;
• (m.) means for moving the mounting apparatus, capable of receiving a signal, for changing the position of the substrate within the mounting apparatus in response to the signal transmitted by the controller;
• and
• (n.) means for adjusting the diameter of the molten metal stream, capable of receiving a signal, for changing the diameter of the molten metal stream in response to the signal received from the controller.