Abstract
A critical part of the billet spray-forming process is the successive intermittent deposition of thin layers of semi-solid aluminium alloy at different points on the top surface of the billet. Each thin layer is made up of a large number of impacted semi-solid spray droplets. As successive layers of alloy are deposited significant re-melting and re-freezing of underlying layers can occur. If the layers become too dry, high porosity will result; if they are too wet, fluid dynamic surface instabilities are possible. In extreme cases no billet will form. The process is essentially incremental, so that heat fluxes within the deposit very close to the top surface play a major role in determining the final deposit microstructure.
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