# US 5,343,926 A · Metal spray forming using multiple nozzles > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 5,343,926 A - Document ID: US5343926A - Status: Granted - Kind: A - Application number: 07/985,525 - Filed: 1992-12-03 - Granted: 1994-09-06 - Earliest claimed: 1991-01-02 - Assignees: Olin Corporation; Osprey Metals Limited - Inventors: Harvey P. Cheskis; W.Gary Watson; Jeffrey S. Coombs; Peter F. Chesney - Web page: https://patentgrep.com/patent/US5343926A ## CPC - C23C 4/185: {Separation of the coating from the substrate} - C23C 4/123: Spraying molten metal - C23C: COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL (making metal-coated products by extrusion B21C23/22; covering with metal by connecting pre-existing layers to articles, see the relevant places, e.g. B21D39/00, B23K; metallising of glass C03C; metallising mortars, concrete, artificial stone, ceramics or natural stone C04B41/00; enamelling of, or applying a vitreous layer to, metals C23D; treating metal surfaces or coating of metals by electrolysis or electrophoresis C25D; single-crystal film growth C30B; by metallising textiles D06M11/83; decorating textiles by locally metallising D06Q1/04) ## 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. ## Claims ### Claim 1 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. ### Claim 2 (depends on 1) A process as in claim 1 wherein the step of providing said first and second volume fractions of solid comprises adjusting the respective temperatures of said first and second streams so that said first stream is hotter than said second stream. ### Claim 3 (depends on 1) A process as in claim 1 wherein the step of providing said first and second volume fractions of solid comprises arranging said streams so that said second stream travels a greater distance from said supply to said collecting member than said first stream. ### Claim 4 (depends on 1) A process as in claim 1 wherein the step of providing said first and second volume fractions of solid comprises adjusting the respective flow rate of the particles of said first and second streams so that the flow rate of said first stream is greater than that of said second stream. ### Claim 5 (depends on 1) A process as in claim 1 wherein said first volume fraction of solid is from about 30% to about 60%. ### Claim 6 (depends on 1) A process as in claim 1 wherein said second volume fraction of solid is from about 50% to about 90%. ### Claim 7 (depends on 5) A process as in claim 5 wherein said second volume fraction of solid is between 60% and 90%. ### Claim 8 (depends on 1) A process as in claim 1 wherein said atomizing comprises directing respective gas flows at said first and second streams, with the temperature of said gas being less than the temperature of said first and second streams. ### Claim 9 (depends on 8) A process as in claim 8 wherein said gas is an inert gas. ### Claim 10 (depends on 8) A process as in claim 8 wherein said gas is non-oxidizing. ### Claim 11 (depends on 9) A process as in claim 9 wherein said gas is non-oxidizing. ### Claim 12 (depends on 8) A process as in claim 8 wherein the step of providing said first and second volume fractions of solid comprises adjusting the flow rate of said gas so that the gas flow rate directed at said second stream is greater than the gas flow rate directed at said first stream. ### Claim 13 (depends on 8) A process as in claim 8 wherein the step of providing said first and second volume fractions of solid comprises adjusting the temperature of said gas so that said temperature of said second spray is less than that of said first spray as they deposit onto said collecting member. ### Claim 14 (depends on 1) The process described in claim 1 wherein said metal or metal alloy is selected to be copper or a copper alloy. ### Claim 15 (depends on 5) A process as in claim 5 wherein said holding step includes maintaining the temperature of said metal or metal alloy in a molten state at a temperature of from about 50.degree. C. to about 200.degree. C. above the melting point. ### Claim 16 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. ### Claim 17 (depends on 16) An apparatus as in claim 16 wherein the means for providing said first and second volume fractions of solids comprise means for adjusting the respective temperatures of said first and second streams so that said first stream is hotter than that of said second stream. ### Claim 18 (depends on 16) An apparatus as in claim 16 wherein the means for providing said first and second volume fractions of solid comprises arranging said streams so that said second stream travels a greater distance from said holding means to said collecting member than that of said first stream. ### Claim 19 (depends on 16) An apparatus as in claim 16 wherein the means for providing said first and second volume fractions of solid comprises means for adjusting the respective flow rates of said first and second streams so that the flow rate of said first stream is greater than that of said second stream. ### Claim 20 (depends on 16) An apparatus as in claim 16 wherein said first volume fraction of solid is from about 30% to about 60%. ### Claim 21 (depends on 16) An apparatus as in claim 16 wherein said second volume fraction of solid is from about 50% to about 90%. ### Claim 22 (depends on 16) An apparatus as in claim 16 wherein said second volume fraction of solid is from about 60% to about 90%. ### Claim 23 (depends on 16) An apparatus as in claim 16 wherein said means for atomizing comprises means for directing respective gas flows at said first and second streams and means for controlling said respective gas temperatures so that the temperature of the gas directed at said first stream is greater than the temperature of the gas directed at said second stream. ### Claim 24 (depends on 16) An apparatus as in claim 16 wherein said gas flows comprise an inert gas. ### Claim 25 (depends on 16) An apparatus as in claim 16 wherein said gas flows are non-oxidizing. ### Claim 26 (depends on 24) An apparatus as in claim 24 wherein said gas flows are non-oxidizing. ### Claim 27 (depends on 16) An apparatus as in claim 16 wherein said means for providing said first and second volume fractions of solid comprises means for adjusting the rate of flow of said respective gas so that the gas flow rate directed at said second stream is greater than the gas flow rate directed at said first stream. ### Claim 28 (depends on 16) An apparatus as in claim 16 wherein said means for holding at least one supply of metal or metal alloy in a molten state includes a means for maintaining said metal or metal alloy at a temperature of from about 50.degree. C. to about 200.degree. C. above the melting point.