Abstract
Spray forming is a new developed advanced metal-forming process, of which the property benefits from rapid solidification. The porosity produced during the atomization progress can obviously decrease the material performance. In this paper, a self-designed Laval-type atomizer is used to improve atomization efficiency. The atomization results show that the atomizer can obtain well atomization effect at a relative lower atomization pressure, and the mass median diameter d50 is 63.5μm and 43.4μm when the atomization gas pressure P0=0.4 and 0.8MPa separately. The technological parameters are optimized by overall considering the atomized droplet size, gas consumption, deposition property, and the metal yield. By the designed atomizer, the as-deposited billet with lower porosity content can be obtained with the technological parameters of the melting temperature T=800°C, atomization pressure P0=0.6MPa, and spray distance h=500mm. Further test with the deposited billet show that the grain size of the spray formed 7055-Al alloy is mainly ranging 10~30μm, which is about one third of that of as-cast billet.
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