Abstract
Spray casting involves sequential atomization and droplet consolidation at deposition rates above 0.25 kg/s, and at least eight independent process parameters must be optimized to achieve the desired preform shape, microstructure and yield. Because effective utilization of spray casting requires control of the preform shape with metallurgical integrity, there is a compelling need to quantify the influence of process parameters on shape, microstructure and overall yield. Coupling this knowledge base with appropriate sensor and control technology establishes a means for process control.
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