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US 5,343,926 AGranted
Metal spray forming using multiple nozzles
AssigneesOlin Corporation, Osprey Metals Limited
InventorsHarvey P. Cheskis, W.Gary Watson, Jeffrey S. Coombs, Peter F. Chesney
Life of this patent
Estimating the term…
Abstract
Metal is spray cast onto a moving substrate using at least two sprays, the first of which has a solid fraction greater than 20% at the time the spray contacts the substrate, but less than the solid fraction of the second spray.
Claims28
A process of spray casting a metal or metal alloy comprising the steps:
- holding at least one supply of metal or metal alloy in a molten state;
- allowing at least first and second streams of said molten metal or metal alloy to issue from said supply;
- atomizing each of said first and second streams into a respective first and second sprays of partially solid particles in an atomization chamber having an inert or non-oxidizing atmosphere effective to extract heat from said particles;
- depositing each of said first and second sprays onto a collecting member wherein said particles solidify into a desired shape;
- moving said collecting member in at least one desired direction during deposition;
- said second spray being arranged to deposit onto said collecting member downstream of said first spray in each desired direction;
- providing said first spray as it deposits onto said collecting member with a first volume fraction of solid greater than 30%;
- and
- providing said second spray as it deposits onto said collecting member with a second volume fraction of solid, said second volume fraction of solid being greater than said first volume fraction of solid whereby the porosity of said metal or metal alloy is substantially minimized.
6 more elements
An apparatus for spray casting a metal or metal alloy comprising:
- a means for holding at least one supply of metal or metal alloy in a molten state;
- a means for allowing at least a first and second stream of said molten metal or metal alloy to issue from said supply;
- a means for atomizing each of said first and second streams into respective first and second sprays of partially solid particles in an atomization chamber having an inert or non-oxidizing atmosphere effective to extract heat from said particles;
- a means for collecting deposits of each of said first and second sprays, said means having a collecting member upon said which said particles solidify into a desired shape;
- with said collecting means further including a means for moving said collecting member in at least one desired direction during deposition;
- said second spray being arranged to deposit onto said collecting member downstream of said first spray in said desired direction;
- a means for providing said first spray as it deposits onto said collecting member with a first volume fraction of solid greater than 30%;
- and
- a means for providing said second spray as it deposits onto said collecting means with a second volume fraction of solid which is greater than said first volume fraction of solid whereby the porosity of said metal or metal alloy is substantially minimized.
6 more elements
Dependencies are inferred from the claim text.