Advanced manufacturing by spray forming: Aluminum strip and microelectromechanical systems
Spray forming is an advanced materials processing technology that converts a bulk liquid metal to a near-net-shape solid by depositing atomized droplets onto a suitably shaped substrate. By combining rapid solidification processing with product shape control, spray forming can reduce manufacturing costs while improving product quality. INEL is developing a unique spray-forming method based on de Laval (converging/diverging) nozzle designs to produce near-net-shape solids and coatings of metals, polymers, and composite materials. Properties of the spray-formed material are tailored by controlling the characteristics of the spray plume and substrate. Two examples are described: high-volume production of aluminum alloy strip, and the replication of micron-scale features in micropatterned polymers during the production of microelectromechanical systems.
- Research Organization:
- Lockheed Idaho Technologies Co., Idaho Falls, ID (United States)
- Sponsoring Organization:
- USDOE, Washington, DC (United States)
- DOE Contract Number:
- AC07-94ID13223
- OSTI ID:
- 32648
- Report Number(s):
- EGG-M--94157; CONF-9411151--3; ON: DE95008615
- Country of Publication:
- United States
- Language:
- English
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