Abstract: A refractory composite structure is formed which comprises a ductile refractory metallic layer with a roughened surface which is tightly bonded to a refractory composite structural shell. The roughened surface is preferably dendritic in form and produced by chemical vapor deposition techniques. The refractory composite structural shell is preferably a carbon-carbon composite formed by applying a carbon filament preform to the roughened surface, infiltrating the preform with a carbon matrix precursor, and carbonizing the precursor.

Abstract: The yield of flat powder (6) of Al, Mg or their alloy is enhanced by forming, on a rotary cooling body (4), a film (8) which can prevent the flat metal powder (8) from sticking to the cooling surface. The film (8) adheres to the cooling surface at a force which is sufficient for forming the film but which enables the film material to adhere to the flat powder which then separates from the cooling body (4). The film consists essentially of at least one liquid lower fatty acid and at least one solid higher fatty acid.

Abstract: A method for fabricating a mold by providing a matrix having a shape to be molded, and spraying molten metal from a spray gun. The spray gun is moved so that the spray gun makes successive passes over the surface of the matrix in a movement direction, shifts in a step direction transverse to the movement direction between passes and turns between passes so that during at least some successive passes metal is deposited from two spray directions in a crisscross pattern. Metal is deposited on the matrix, forming a shell which is removed from the matrix and used as a mold.

Abstract: A system and method of electroslag refining of metal is taught. The system and method includes the introduction of unrefined metal into an electroslag refining process in which the unrefined metal is first melted at the upper surface of the refining slag. The molten metal is refined as it passes through the molten slag. The refined metal is collected in a cold hearth apparatus having a skull of refined metal formed on the surface of the cold hearth for protecting the cold hearth from the leaching action of the refined molten metal. A cold finger bottom pour spout is formed at the bottom of the cold hearth to permit dispensing of molten refined metal from the cold hearth. The dimensions of the cold finger apparatus pour spout are controlled by positioning a retaining means around the outer surface of the pour spout thereby controlling the flow rate of molten metal through the cold finger apparatus.

Abstract: The object of the invention is to provide a new method for extinguishing fires. The method is advantageously used for fighting fires in engine rooms and similar spaces. According to the method, the fire is extinguished or at least suppressed by means of concentrated fog sprays with strong penetrating power, by utilizing high operating pressure, which is gradually decreased for the provision of spread fog-like liquid spraying providing for effective heat absorption and control of fire. The extinguishing liquid is preferably delivered to spray heads (43, 44, 45) by using hydraulic accumulators (41, 41a).

Abstract: A thermal reactor system that produces nanoscale powders by ultra-rapid thermal quench processing of high-temperature vapors through a boundary-layer converging-diverging nozzle. A gas suspension of precursor material is continuously fed to a thermal reaction chamber and vaporized under conditions that minimize superheating and favor nucleation of the resulting vapor. According to one aspect of the invention, the high temperature vapor is quenched using the principle of Joule-Thompson adiabatic expansion. Immediately after the initial nucleation stages, the vapor stream is passed through the nozzle and rapidly quenched through expansion at rates of at least 1,000.degree. C. per second, preferably greater than 1,000,000.degree. C. per second, to block the continued growth of the nucleated particles and produce a nanosize powder suspension of narrow particle-size distribution.

Abstract: An apparatus for the accurate formation of a free-form three-dimensional article comprises providing a supply of substantially uniform size metal droplets of a desired material wherein each droplet has a positive or negative charge in an enclosed environment. The supply of droplets is focused or aligned into a narrow stream by passing the droplets through or adjacent an alignment mechanism which repels each droplet toward an axis extending through the alignment mechanism. The droplets are deposited in a predetermined pattern at a predetermined rate onto a target to form the three-dimensional article without the use of a mold of the shape of the three-dimensional article.

Abstract: Methods for controlling the superheat of the stream of molten metal from an electroslag refining apparatus is taught. The methods include the introduction of unrefined metal into an electroslag refining process apparatus in which the unrefined metal is first melted at the upper surface of the refining slag. The molten metal is refined as it passes through the molten slag. The refined metal is collected in a cold hearth apparatus having a skull of refined metal formed on the surface of the cold hearth for protecting the cold hearth from the leaching action of the refined molten metal. A cold finger bottom pour spout or exit orifice is formed at the bottom of the cold hearth to permit dispensing of molten refined metal from the cold hearth.

Abstract: The present invention is directed to an apparatus for manufacturing a free standing solid metal part. In the present invention metal droplets are ejected in a nozzleless fashion from a free surface pool of molten metal by applying focused acoustic radiation pressure. The acoustic radiation pressure is produced by high intensity acoustic tone bursts emitted from an acoustic source positioned at the bottom of the pool which directs the acoustic energy at the pool surface. The metal droplets are electrostatically charged so their trajectory can be controlled by electric fields that guide the droplets to predetermined points on a target. The droplets impinge upon the target and solidify with the target material. The accretion of the electrostatically directed solidified droplets forms the free standing metal part.

Abstract: A method and apparatus for the accurate formation of a three-dimensional article comprises providing a first quantity and a second quantity of substantially uniform size droplets of a desired material wherein each droplet has a positive or negative charge. Each quantity of droplets is focused or aligned into a narrow stream by passing the droplets through or adjacent an alignment means which repels each droplet toward an axis extending through the alignment means. The droplets are deposited in a predetermined pattern at a predetermined rate onto a target to form the three-dimensional article without a mold of the shape of the three-dimensional article. The droplets of the first quantity and the second quantity are supplied at different distances, whereby the droplets of the first quantity bond to each other and the droplets of the second quantity do not bond to each other or to the first quantity of droplets.

Abstract: A method for forming a replica stamper for use in mass producing an optical disk, wherein the optical disk has a plurality of tracks arranged spirally or concentrically, and each of the tracks includes a recess and a protrusion for recording information signals thereon, comprises the steps of: (a) preparing a master stamper having a top surface and a flat bottom surface, wherein the top surface of the master stamper includes a plurality of tracks corresponding to the plurality of tracks of the optical disk; (b) depositing a buffer layer on the top surface of the master stamper; (c) forming a replica stamper on top of the buffer layer; (d) disengaging the master stamper from the buffer layer and the replica stamper; and (e) removing the buffer layer from the replica stamper.

Abstract: A method for the accurate formation of a three-dimensional article comprises providing a supply of substantially uniform size droplets of a desired material wherein each droplet has a positive or negative charge. The supply of droplets is focused or aligned into a narrow stream by passing the droplets through or adjacent an alignment mechanism which repels each droplet toward an axis extending through the alignment mechanism. The droplets are deposited in a predetermined pattern at a predetermined rate onto a target to form the three-dimensional article without the use of a mold of the shape of the three-dimensional article.

Abstract: Method of making a rapid tool, comprising: making a plastic pattern of the tool by free form fabrication techniques following a computer aided design, the design having a base and no undercuts taken in a direction perpendicular to base; constructing a ceramic mold as the inverse of the pattern; separating the pattern from the mold by a separating movement in a direction perpendicular to the base to leave a surface defining a casting cavity within the mold; and thermally spraying tool steel particles against the casting cavity surface is a thickness exceeding 1 inch while rapidly cooling the sprayed particles to effect a net shape tool without the need for further working or heat treatment.

Abstract: A process for producing an amorphous alloy ribbon by the single roll method is disclosed, which comprises injecting through a slot disposed at a nozzle tip a molten alloy having the composition represented by the general formula:(Fe.sub.1-a M.sub.a).sub.100-x-y-z-b Cu.sub.x Si.sub.y B.sub.z M'.sub.bwherein M is Co and/or Ni, M' is at least one element selected from the group consisting of Nb, Mo, W and Ta, and a, x, y, z and b satisfy the relationships: 0.ltoreq.a.ltoreq.0.1, 0.5.ltoreq.x.ltoreq.2 (atomic %), 5.ltoreq.y.ltoreq.20 (atomic %), 5.ltoreq.z.ltoreq.11 (atomic %), 14.ltoreq.y+z.ltoreq.25 (atomic %) and 2.ltoreq.b.ltoreq.5 (atomic %), provided that the ratio of y to z (y/z) is in the range of 0.5.ltoreq.y/z.ltoreq.3, onto a cooling wheel comprising a Cu alloy containing Be in an amount of 0.05 to 3.0% by weight. This process is advantageous in that the position of peel of the amorphous alloy ribbon formed on the cooling wheel can be controlled.

Abstract: A method for making double-wall airfoil for applications such as the blades and vanes of gas turbine engines by depositing an airfoil skin over an inner support wall which is separately formed and contains channels filled by a channel filling means. The channel filling means is removed thereby forming integral channels within the double-wall for circulating a cooling gas adjacent to the airfoil skin. The airfoil skin deposited may be a metal alloy skin or a microlaminate structure, including microlaminate composite structures.

Abstract: Embossed, finely-divided, thin, bright-metal particles are prepared by forming an embossed release surface on at least one side of a carrier sheet in which the embossed pattern comprises a diffraction grating having from about 5,000 to 11,000 grooves per cm. A metal film is deposited on the release surface so that the metal film conforms to the embossed surface. The carrier sheet is passed with the release surface and the metal film through a release environment which causes the release surface to separate from the metal film. The metal film is removed from the release surface in a particulate form to produce metal particles substantially free of the release surface. The particles are collected in a solvent which is non-reactive with the metal. The metal particles are then broken into pigment particles having an average diameter between about 10 to about 50 microns. The film may also take the form of an optical stack.

Abstract: A method of fabricating a metal casket by assembling a body containment mold and a lid mold. Each of the molds has inner and outer surfaces. A release mechanism is separately applied to the surfaces of each of the molds. A body containment compartment is formed by depositing a layer of metal on the inner surface of the body containment mold until a desired thickness is achieved. A lid component is formed by depositing a layer of metal on the inner surface of the lid mold until a desired thickness is achieved. Structural polymeric material is then applied to the inner surfaces of the body containment compartment and the lid component. Thereafter, the body containment compartment and the lid component are removed from their respective molds and are hingedly connected to one another.

Abstract: A method and apparatus for the accurate formation of a three-dimensional article comprises providing a supply of substantially uniform size droplets of a desired material wherein each droplet has a positive or negative charge. The supply of droplets is focused or aligned into a narrow stream by passing the droplets through or adjacent an alignment means which repels each droplet toward an axis extending through the alignment means. The droplets are deposited in a predetermined pattern at a predetermined rate onto a target to form the three-dimensional article without a mold of the shape of the three-dimensional article. A supply of support material is provided in a predetermined pattern adjacent the deposited droplets. The support material receives a further supply of droplets which form a part of the three-dimensional article.

Abstract: A stream of overheated metal melt is applied from a container through a pouring nozzle as a closed jet, or in such a way as to be split up into drops by a gaseous medium, at a pouring point, to the inner surface of a strip coil or composite body also rotating in a mold body. Thus, an initially liquid metal film is produced to which a liquid coolant, preferably a low-temperature liquefied gas such as argon or nitrogen, is applied from a cooling nozzle at a cooling point which is offset in the direction of rotation relative to the pouring point. The coolant dissipates a substantial portion of the excess and melt heat of the metal film, mostly due to vaporization of the liquid coolant. Depending on the residual heat which it still has after the cooling operation, the metal film either remains isolated from the innermost metal layer applied beforehand, so that a strip coil develops, or melts with the metal layer so that a rotationally symmetrical composite body forms.

Abstract: A dispersion-strengthened copper alloy is disclosed having an exceptional combination of strength, ductility, and thermal conductivity. The copper alloy comprises: copper, 0.01 to 2.0 weight % boron and 0.1 to 6.0 weight % cobalt, and cobalt-boride disperoids that range in size between 0.025 and 0.25 microns in diameter. A copper alloy is made by rapid solidification of the melt into a powder. Strong, thermally conductive articles can be made by compacting the powder at temperatures below the melting temperature of the copper alloy, and optionally warm working, cold working, and annealing.

Abstract: A composition and method for producing a low density, high stiffness aluminum alloy which is capable of being processed into structural components having a desired combination of tensile strength, fracture toughness and ductility. The method includes the steps of forming, by spray deposition, a solid Al-Li alloy workpiece consisting essentially of the formula Al.sub.bal Li.sub.a Zr.sub.b wherein "a" ranges from greater than about 2.5 to 7 wt %, and "b" ranges from greater than about 0.13 to 0.6 wt %, the balance being aluminum, said alloy having been solidified at a cooling rate of about 10.sup.2 to 10.sup.4 K/sec. The method further includes several variations of selected thermomechanical process steps for: (1) eliminating any residual porosity which may be present in the workpiece as a result of the spray deposition step; and (2) producing components for a wide range of applications.

Abstract: A method of producing polymeric foam patterns for use in evaporable foam casting. A positive three-dimensional model of the metal part to be cast is made by a layered prototyping process in which layers of sheet material are bonded in superimposed relation and the contour of the part to be cast is cut into each layer as it is applied to preceding layers to provide the model. A metal, such as copper, is then deposited on the working surface of the model to provide a rigid self-supporting shell having a surface which is the negative image of the part to be cast. The shell, after separation from the model, is then mounted in a die casting mold with the negative surface bordering a die cavity. Beads of a polymeric material, such as polystyrene, are introduced into the die cavity and heated to fuse the beads and provide a foam pattern which is identical in configuration to the metal part to be ultimately cast.

Abstract: Ballistic armor is fabricated by spraying atomized particles of molten ballistic armor metal alloy onto a collector utilizing a pressurized inert gas which impacts upon a controlled feed of the molten armor metal alloy. Dual hardness armor plate and parts are produced by spraying a second layer of a different armor metal alloy onto the first layer either before the first layer has completely solidified or while a semi-liquid surface exists on the first layer.

Abstract: A method and apparatus for the production of a deposit such as a bar (1) is provided. The deposit has a longitudinal outer surface (2) and a front face deposition surface (3). The spray deposition comprises atomized droplets produced by outer and inner sprays (4 and 5). The outer and inner sprays (4 and 5) are both directed such that, during deposition, a substantial proportion of droplets from both sprays are deposited on the front face (3) of the forming deposit. The inner spray (5) has a higher gas to metal ratio than the outer spray allowing an increase of both deposition and final product yield.

Abstract: Making a tire mold by spraying molten atomized metal on a model to form a metal shell and then reinforcing the shell with a resin backing to form a mold segment for the tire mold. Modular shoe container assemblies have replaceable backing members for making different size molds and flat plate spacers for providing different thicknesses of the mold segment. In one embodiment a slide block is used for one side of the cavity whereby a sole plate is eliminated.

Abstract: A method of making quasicrystalline alloy particulates wherein an alloy is superheated and the melt is atomized to form generally spherical alloy particulates free of mechanical fracture and exhibiting a predominantly quasicrystalline in the atomized condition structure. The particulates can be plasma sprayed to form a coating or consolidated to form an article of manufacture.

Abstract: A method of producing continuous lengths of metallic strip comprises the steps of forming a spray of molten metal particles, causing the particles to be deposited onto a surface of a hollow receptor roll, rotating and internally heating the receptor roll to form continuous lengths of metallic strip, holding the deposited particles in contact with the receptor roll surface by means of a roll positioned immediately upstream of the knife in the direction of rotation of the receptor roll, and peeling from the receptor roll surface such continuous lengths of metallic strip by means of a knife positioned adjacent to or in contact with the receptor roll surface. Apparatus for performing this process is also disclosed.

Abstract: There is disclosed methods for the manufacture of a metal matrix composite having a metal or metal alloy matrix and a uniform dispersion of a second phase. The second phase is either a refractory metal or a nonmetal. An element which reacts with both the matrix and the second phase is added to increase the loathing density of the second phase and to improve adhesion between the components of the composite. When the metal alloy matrix is copper or a copper based alloy, suitable reactive elements include zirconium, titanium, chromium and mixtures thereof.

Abstract: Methods and apparatus for separating a mandrel having a tapered end portion from an article formed thereon comprising: (a) providing the mandrel having an opening in the tapered end portion; (b) plugging at least a substantial portion of the opening with a member which presents a deposition surface for the formation of the article; (c) forming the article having a tapered end portion on the mandrel, including on the deposition surface of the member; and (d) pushing the member against the inside surface of the tapered end portion of the article to move the article away from the mandrel, thereby forming a gap between the article and the mandrel.

Abstract: Methods for manufacturing a self-supporting substrate having a plurality of spaced-apart needles (spikes or microcapillaries) projecting upwardly from a major surface of the substrate. In a preferred method, metal is deposited onto a porous membrane such that the metal extends into the pores, after which the membrane is dissolved.

Abstract: There is provided an apparatus and method for the manufacture of metallic articles. A molten metal stream is disrupted, such as by gas atomization, to form a plurality of molten metal droplets. The molten metal droplets pass through a cooling zone having a length sufficient to allow up to about 30 volume percent of each of the droplets to solidify. A mold then receives and completes solidification of the metal droplets. When under about 30 volume percent of the droplets is solid, the droplets retain liquid characteristics and readily flow within the mold.

Abstract: To predict the rate of flow of cooling fluid (gas) through a passage system in a proposed airfoil during operation of a Jet engine, a full size model of the passage system is prepared. The flow of air or other gas is conducted through the model of the passage system. The characteristics of the flow of air or gas through the model of the passage system is determined to enable the characteristics of the flow of cooling fluid through the passage system in the proposed airfoil to be predicted. The model of the cooling fluid passage system in the proposed airfoil is formed by covering the pattern with a layer of metal. The pattern is removed from the covering to form a passage system having a configuration corresponding to the configuration of the cooling fluid passage system in the proposed airfoil.

Abstract: An apparatus and method for producing a rapidly solidified ingot characterized by a fine scale microstructure capable of precipitating uniformly dispersed fine particles. A charge of the material is placed in a crucible and heated by a furnace to melt the charge. The melt is discharged from the crucible in a stream along a pouring axis. An ingot mold is oriented at an angle with respect to the pouring axis so that the stream is received in the mold. As the melt is being poured into the mold, the mold is rotated about its central axis at a predetermined speed to continuously shear, both circumferentially and downwardly, a thin layer of the melt from the stream as the stream contacts the sidewall surfaces of the mold. The thin layer is rapidly solidified by the extraction of heat through the mold and is formed, as said ingot mold fills and successive layers are solidified, into an ingot having a fine microstructure capable of developing uniformly dispersed fine particles.

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: A method of manufacture of a net form product, including directing a stream of liquid from a nozzle onto a collector of the shape of the desired product, applying an amplitude and time dependent modulated disturbance to the stream to produce a droplet stream, and with the nozzle and collector in a chamber, controlling the chamber environment. An apparatus for manufacturing a net form product having a source of molten material under pressure, a support for positioning a product collector in a chamber with the collector defining a desired product, a droplet stream generator positioned within the chamber and including a nozzle, a conduit for conducting molten material from the material source to the generator nozzle, a mechanism, typically a modulator, for amplitude and time dependent modulation disturbance of the droplet stream, and a drive mechanism for relative movement of the nozzle and support.

Abstract: Tools and dies are made from a master pattern by making a hard chromium electroformed shell from the pattern, supporting the pattern and filling it with tool steel which applied by spray deposition of molten particles, the deposit being continuously densified by peening as it is made.

Abstract: A method of producing long size preform is disclosed in which: a long size cylindrical collector extended in a manner penetrating a chamber is moved lengthwise thereof while it is rotated; a preheated metal layer is formed on the outer periphery of the collector by adhering a molten metal to the collector within the chamber at the upstream side in the traveling direction of the collector; and a molten metal is caused to be cumulated by spray deposit on the metal layer formed on the outer periphery of the collector by spraying the molten metal from the ceiling within the chamber at the downstream side in the traveling direction of the collector by way of an atomizer which ejects an inert gas. By using this method, porosity occurring on the collector side of the preform may be inhibited.

Abstract: A system and method for manufacturing an article that is formed by the incremental buildup of layers on a work surface contains a material deposition station to deposit the layers. In addition, a plurality of processing stations are employed. Each processing station performs a separate function such that when the functions are performed in series, a layer of the article is produced and is prepared for the deposition of the next layer. An article transfer apparatus repetitively moves the work surface and any layers formed thereon selectively among the deposition station and the processing stations. The article transfer apparatus continues to move between the processing stations until each layer is processed and a completely manufactured article is produced.

Abstract: A method for forming a three-dimensional object by applying segments of complementary material and deposition material so as to form layers of material. Selected segments of material are then shaped after one or more segment is formed. In this manner, layers of material form a block containing the object made of deposition material and surrounded by complementary material. Then, the complementary material which serves as a support structure during forming is removed. Preferably, the complementary material has a lower melting temperature than the deposition material and is removed by heating the block. The deposition material and complementary material are preferably applied by thermal spray deposition but may be applied by weld deposition, liquid slurry, gravity drop or any manual means such as a hand sifter. It is also preferred but not necessary to use masks when applying the material.

Abstract: A method for producing a rotationally symmetrical body from a molding material, such as a molten metal, which comprises atomizing the molding material in liquid form through a spraying nozzle that is disposed relative to a spray receiving the sprayed molding material on an initial position of said surface, forming a level of liquid molding material on said spray receiving surface and molding material, forming a controllably rotating body of said liquid molding material while it is solidifying, said solidifying rotating body having a diameter, drawing the so-formed body downwardly from said initial position while continuing its rotation, continuously forming said body at said initial position, monitoring the diameter values of the rotating body at a plane adjacent to said initial position, and controlling said rotation by said diameter values.

Abstract: A metal is attached on a passage-forming core by electrocasting to provide a primary metal layer. A plurality of grooves are formed on the primary metal layer and are filled with filler of low melting point. A metal is attached on the primary metal layer by electrocasting to provide a secondary metal layer. Openings are formed on the secondary metal layer adjacent to its opposite ends so as to communicate with the grooves. The filler in the grooves is melted to provide a plurality of coolant passages. The openings are filled with manifold-forming cores made of filler with low melting point. A metal is attached on the manifold-forming cores by electrocasting to provide tertiary metal layers. Through holes are formed on the tertiary metal layers. The passage-forming core is dissolved and the manifold-forming cores are melted to provide a gas passage and manifolds.

Abstract: A process and apparatus for producing a spray of atomized metal droplets includes providing an apparatus that forms a spray of molten metal droplets, the apparatus including a metal source and a metal stream atomizer, producing a stream of liquid metal from the metal source, and atomizing the stream of liquid metal with the metal stream atomizer to form the spray of molten metal droplets. A controlled spray of atomized metal droplets is achieved by selectively varying the temperature of the droplets in the spray of molten metal droplets, the step of selectively varying including the step of varying the flow rate of metal produced by the metal source, responsive to a command signal, and sensing the operation of the apparatus and generating the command signal indicative of the operation of the apparatus. The step of atomizing may be accomplished by directing a flow of an atomizing gas at the stream of liquid metal, and then selectively controlling the flow rate of the atomizing gas.

Abstract: Disclosed is a method and an apparatus for producing rapidly-solidified flake particles, which combines centrifugal atomization with metal substrate cooling. A stream of molten metal is disintegrated centrifugally into droplets by a rotating disk. Then the molten droplets are solidified as flake particles as soon as impinging upon the annular planar surface of a cooled rotating concave disk. The solidified flake particles are subsequently departed from the annular planar surface by the centrifugal force and collected in a chamber.

Abstract: A free-form, three-dimensional, solid-phase object (30) is produced from droplets (24) of liquid-phase material having appreciable surface tension and well-defined solidification properties. The liquid-phase material is ejected from an ejection head (20) in discrete droplets onto a substrate (98). The temperature, frequency, size, and trajectory of the droplets and the relative speed of motion between the substrate and the ejection head are adjusted to compensate for the physical properties of the liquid-phase material and the heat dissipation characteristics of the growing object to form a desired object (212).

Abstract: A molten metal gas-atomizing spray-depositing apparatus has an atomizer which employs a pressurized gas flow for atomizing a stream of molten metal into a spray pattern of metal particles being initially hotter than the solidus temperature of the metal. The apparatus also has a substrate system which includes an outer substrate of metallic foil and an inner substrate for supporting the outer substrate. The outer foil substrate is movable relative to the metal particles in the spray pattern thereof and disposed below the atomizer for receiving on a surface of the foil a deposit of the particles in the spray pattern to form a product on the outer foil substrate. The outer foil substrate is of a thickness which is less than a predefined maximum thickness at which the capacity of the foil to absorb heat from the deposit is equal to the latent heat and super heat, if present, of the deposit.

Abstract: Ballistic armor is fabricated by spraying atomized particles of molten ballistic armor metal alloy onto a collector utilizing a pressurized inert gas which impacts upon a controlled feed of the molten armor metal alloy. Dual hardness armor plate and parts are produced by spraying a second layer of a different armor metal alloy onto the first layer either before the first layer has completely solidified or while a semi-liquid surface exists on the first layer.

Abstract: The present invention provides a method of forming a free standing shape made of a material containing refractory metal, which entails providing a mandrel in a CVD enclosure, injecting a refractory halide gas and a reducing gas in the enclosure, reacting the gases in the enclosure to generate a material containing refractory metal, growing a layer of the material containing refractory metal on the mandrel and removing the mandrel to obtain the free standing shape, wherein the reducing gases is a silicon hydride gas or a mixture thereof.

Abstract: A method for forming a reinforced metal structure having a filamentary reinforcement evenly distributed therein is taught. The structure is formed by the plasma spray deposit of matrix metal onto and about a filamentary reinforcement. A plurality of layers of filamentary reinforcement are embedded in the structure. Between each layer an abrasive grinding and smoothing operation is performed to render the surface of the spray deposited metal smooth and even and to permit the even spacing of filament reinforcement on the spray deposited surface. The abrasive grinding of the spray formed surface does not have deleterious effects on the property of the composite reinforced structure which is formed.

Abstract: A method of manufacture of a net form product, including directing a stream of liquid from a nozzle onto a collector of the shape of the desired product, applying an amplitude and time dependent modulated disturbance to the stream to produce a droplet stream, and with the nozzle and collector in a chamber, controlling the chamber environment. An apparatus for manufacturing a net form product having a source of molten material under pressure, a support for positioning a product collector in a chamber with the collector defining a desired product, a droplet stream generator positioned within the chamber and including a nozzle, a conduit for conducting molten material from the material source to the generator nozzle, a mechanism, typically a modulator, for amplitude and time dependent modulation disturbance of the droplet stream, and a drive mechanism for relative movement of the nozzle and support.

Abstract: A method and apparatus for the casting of metals in which a molten stream of metal is atomized into a spray of highly liquid droplets. The droplets are deposited on a moving substrate such as an endless belt provided with side dams. The droplets flow in a direction transverse to the direction of movement of the substrate and are contained by the side dams. The droplets may have an average size of 300 microns and the spray may have a liquid to solid ratio of at least 50%. This arrangement overcomes the problems of splashing and turbulence caused by the relative flow between the melt and the belt in regular belt casting and overcomes porosity problems associated with spray casting.