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.

Abstract: There is provided a method of spray deposition in which a stream of liquid metal or metal alloy is atomized inside a spray chamber into a spray of atomized droplets. A metal or metal alloy collector is rotated about an axis transverse to the mean axis of the spray and in the path of the spray so that a deposit is formed about the collector with a bond between the deposit and the collector sufficient to isolate the interface from oxygen penetration. The collector is then retained as an integral part of the final product and further processed to substantially eliminate porosity in the region of the bonded interface. The collector and the deposit may be the same or different materials, and the bond between the deposit and the collector is preferably enhanced by plasma heating in the region disposition. The invention also provides a plant for carrying out the preferred method arc plasma heating.

Abstract: A metal, e.g. in the form of a shaped article, is made by atomizing a stream of molten metal and directing the atomized stream at a collecting surface to form a deposit of the metal. Fine, solid particulate material of different composition from the metal, e.g., nonmetallic particles, and of mean particle size less than 20 micrometers, preferably less than 10 micrometers, is applied to the stream or spray so that it becomes incorporated into the deposit. The particulate material is applied by generating a fluidized bed thereof and feeding it from the bed into the stream or spray. Uniform dispersion of material such as SiC at a high volume percentage (e.g. greater than 15%) may be achieved.