Abstract
Spray forming is a single step gas atomization/deposition process which yields ferrous and non-ferrous near net shape preforms. It has proven to be a viable, cost effective alternative to conventional metal working technology for the production of material preforms with properties surpassing those of their cast and wrought counterparts. Current Navy programs are aimed at optimization of the process, certification of the spray formed products and industrialization of the technology. This includes the development of robust, real-time sensors interfaced with an automated fuzzy logic controller and expanded motion control system. The system will have the capability to manufacture low cost, improved performance, non-symmetric components currently producible only by casting or forging. In addition commercially available spray formed piping from foreign sources is currently being evaluated and certified for near term use in the fleet. Industrialization efforts are underway to establish domestic capabilities as there are no commercial facilities in the United States to date. The Navy has just initiated a manufacturing technology program, the intent of which is to develop a commercial plant in the United States capable of producing large military components. This paper will describe the process and program status. Results and comparative data will be presented and potential new applications discussed.
Published Version
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