Spray Forming (Spray Casting)

Spray forming, or spray casting is a process to cast billets or other simple shapes via a semi solid process. The molten metal is sprayed through a ceramic nozzle onto a rotating copper wheel. The spray drops are semi-liquid. The droplets form a billet after a while. The resulting high cooling rate produces a homogenous microstructure. The tensile strength and hardness is higher than for conventional wrought processing. The finished sprayed billet with a density of up to 94% will undergo secondary processing like extrusion, pressing or forging. Typical alloys are Aluminum, and Nickel-based Superalloys.

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