Molten metal spray forming apparatus

A molten metal spray forming system comprising:

• a manifold having an aperture therethrough for the passage of a molten metal stream, the manifold including a plurality of convergent gas jet means surrounding the aperture and molten metal stream;
• a pair of opposed gas conduit means connecting the manifold therebetween for oscillating the manifold and for providing gas flow thereto;
• gas supply means, operatively connected to the gas conduits for supplying a gas thereto, the gas flow into the manifold issuing from the gas jet means in convergent relationship to impact the passing molten metal stream such that the metal stream is converted into a spray pattern of small molten metal droplets for deposition on a collector surface;
• programmable computer controlled electric motor drive means, operatively connected to the gas conduit means, for oscillating the manifold;
• and
• gas flow control means including a closure member operatively overlaying a gas inlet, the gas flow control means being operatively connected to the gas conduit means, for varying the flow of gas through the gas conduit into the manifold thereby changing the ratio of gas to metal in the spray pattern.

A molten metal spray forming atomizer comprising:

• a manifold defining an aperture having a center through the manifold adapted to pass a molten metal stream through the aperture, the manifold having gas jets positioned therein surrounding the aperture, the manifold being adapted to receive a gas therein under pressure and to direct the gas through the gas jets to engage the molten metal stream after the molten metal stream has passed through the aperture so that the metal stream is atomized into a spray pattern having a gas/metal ratio;
• mounting means for angular adjustment rotation of the atomizer about a transverse axis of the aperture;
• and
• a gas control means comprising:
• a gas inlet operatively positioned in the mounting means;
• a gas chamber enclosing the inlet in the mounting means;
• and
• a gas flow slide valve assembly including a closure member operatively overlaying the gas inlet so that oscillation of the mounting means causes the gas inlet to be progressively closed off or progressively exposed to gas flow from the gas chamber thereby changing the gas/metal ratio of the spray pattern.