Abstract
Surface temperatures and the corresponding liquid fractions in a spray deposited commercial 2000 series Al alloy have been measured accurately by plunging thermocouples into sprayforms during growth. Two colour pyrometry was shown to be reasonably accurate for measuring surface temperature but only under constant, or preferably zero, overspray density. Yield, porosity and grain size have been shown to be strong functions of the top surface temperature and liquid fraction in the sprayform during spray deposition, over a wide range of liquid fraction. The final grain size cannot be predicted from the liquid fraction using conventional coarsening theories, because they do not take into account variations in nucleation density and are not applicable at low liquid fractions. Rapid variation of liquid fraction with top surface temperature during spray deposition implies that to maintain optimum conditions requires control of the temperature to within at least ±2°C.
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