Analysis of solidification in spray atomized and codeposited metal-matrix composites

The influence of the injection of reinforcing particles (for the production of metal matrix composites) and the droplets-to-substrate heat transfer on the resulting microstructural uniformity of spray atomized and codeposited composite material was analyzed. It was demonstrated that tailoring the microstructures and the reinforcement volume percent in the deposited material is feasible. The critical process parameters: the atomization pressure, the melt flow rate, the substrate to pouring-tube orifice distance, the reinforcement particles injection location and rate can all be adequately chosen in order to obtain any desired microstructure, grain size, reinforcement volume percent, with the additional benefit, if wanted, of rapid solidification processing.