Abstract: Method and apparatus for controlling stresses in a spray form process makes use of one dimensional modeling in which characteristics of a geometrical point are quantified by iterative detection, such as taking a surface temperature reading using a pyrometer. This temperature information is used in a one dimensional simulation to predict characteristics for a column from the point down through a spray-formed article to an interface with a substrate. The modeling technique can used with a plurality of geometrical points to model the whole article, and the one dimensional simulation can be integrated with robotic spray-forming controls to minimize residual stress in the spray-formed article.

Abstract: Method and apparatus for controlling a spray-forming process incorporating time, temperature, and transformation dependent stress relief techniques involves the manipulation of both temperature and time for strategic phase changes that result in a specific and planned volumetric increase. This manipulation is made based on controlling ongoing spray parameters to spray-form an article having a mixed-phase and interspersed makeup of metallic phases that minimizes residual stress in the article.

Abstract: A facsimile of article to be produced by tooling is laid in register with a first tooling part and sprayed metallic material is deposited over the first tooling part and the facsimile of the article in order to form a second tooling part. The first tooling part typically comprises a metallic material and portions of the first and second tooling parts bounding the article facsimile are typically in metal to metal contact with one another. The tooling parts are separated and the article facsimile removed.

Abstract: A method for implementing pre-heat treatment before spray forming begins to achieve stress control in the manufacture of a spray formed metallic article involves preheating either or both of a spray forming cell environment and a mold substrate, initiating application of the metallic spray forming material onto the mold substrate, and causing substantially homogenous initial metallic phase transformations from the austenite phase via a predetermined relationship between the initial application temperature of the spray-forming material and the initial temperature of either or both of the preheated cell environment and the preheated mold substrate.

Abstract: Porous regions or void regions of spray deposited articles of one composition are infilled with molten material of a differing composition which subsequently solidifies. The molten material flows to infill the porous or void regions under the influence of applied pressure or capillary type action. Typically, the sprayed material is molten metallic material, and the void porosity filling material is also metallic in composition but having a lower melting point.

Abstract: Atomized metal is deposited metal onto a substrate so as to cause at least partial solidification of the deposited metal; further atomized metal is deposited onto the partially solidified deposited metal on the substrate; and the metal deposited onto the partially solidified deposited metal is allowed to fully solidify on the substrate; the cooling of the further deposited metal, and the composition of the metal and/or of a gas used in the atomization of the further atomized metal being tailored such that volumetric contraction on solidification and cooling of the further deposited metal is compensated for, when the deposited metal has been cooled to ambient temperature, by volumetric expansion in a reaction or phase change in the further deposited metal.

Abstract: Metallic articles having heat transfer channels are produced by solidification of molten metallic material about pre-formed channel defining members such that a solidified metallic deposit having heat transfer channels is formed. The channel defining members may be in the form of either solid elements (which are subsequently removed to leave the channels), or conduit elements (which may remain permanently embedded in the article). Moulds, dies, cores and other tools for use in moulding or casting of plastics and metals are particularly suitably formed by the process, the heat transfer channels being used for cooling of the respective articles during use. The molten metallic material is preferably deposited by spray forming utilizing one or more sprays of molten metallic material.