Method of spray forming readily weldable and machinable metal deposits

A method of spray forming a readily weldable steel article having a Rockwell C hardness less than about 35, said method comprising:

• (a) providing a ceramic spray forming pattern;
• (b) heating the spray forming pattern to a sustained temperature sufficient to prevent internal stress formation in carbon steel having a carbon content of between about 0.01 and less than about 0.3 weight percent when deposited on the heated spray forming pattern, wherein the sustained temperature is above about 600° C.;
• (c) spraying molten metallic particles, originating from a sprayable steel material in which the carbon content, when deposited on the spray forming pattern, is between about 0.01 and less than about 0.3 weight percent, onto the spray forming pattern heated to the sustained temperature;
• (d) maintaining the sprayed metallic particles on the spray forming pattern above about 300° C. during spraying in step (c);
• and
• (e) allowing the sprayed metallic particles to air cool to form the steel article having a thickness of at least about 0.5 inches and having a carbon content of between about 0.01 and less than about 0.3 weight percent on the spray forming pattern.

A method of spray forming a readily weldable steel article having a Rockwell C hardness less than about 35, said method comprising:

• (a) providing a ceramic spray forming pattern;
• (b) heating the spray forming pattern to a sustained temperature sufficient to prevent internal stress formation in carbon steel having a carbon content of between about 0.01 and less than about 0.3 weight percent when deposited on the heated spray forming pattern, wherein the sustained temperature is above about 600° C.;
• (c) spraying molten metallic particles, originating from a sprayable steel material in which the carbon content, when deposited on the spray forming pattern, is between about 0.01 and less then about 0.3 weight percent, onto the spray forming pattern heated to the sustained temperature;
• (d) maintaining the sprayed metallic particles on the spray forming pattern above about 300° C. during spraying in step (c);
• and
• (e) allowing the sprayed metallic particles to cool to room temperature to form the steel article having a thickness of at least about 0.5 inches and having a carbon content of between about 0.01 and less than about 0.3 weight percent on the spray forming pattern.