The Spray Forming of Superalloys

Spray forming involves the gas atomization of a stream of molten metal to form droplets, and depositing the droplets on a collector before they have solidified. By manipulating the stream and/or the collector, a variety of useful shapes such as disks, bars, sheet, and plate can be made. As a consequence of rapid solidification, the product is homogeneous and is comprised of small, equiaxed grains, making it well suited to further processing. Discussed are the spray forming of 718 and Rene 95, and the properties after heat treatment, both as-deposited and after forging. Also reviewed are recent developments with respect to the processing of a range of near-net shape products.