Fabrication of AMCs by spray forming: Setting of cognition and social parameters to accelerate the convergence in optimization of spray forming process

Spray forming (also known as spray atomization and deposition) is of interest as a manufacturing technique that combines near-net-shape capabilities with the structural control available through rapid solidification. The present article focuses on development of a comprehensive method to optimize a number of parameters in the spray deposition processing of Al matrix composites including melt superheat, nozzle to substrate distance, metal to gas flow rate and high heat removal rate at the droplet–gas interface. The SiC particles reinforced Al matrix composites were produced by the spray atomization and co-deposition process using optimized parameters. Microscopic investigations of the composite specimens indicate that the distribution of SiC in the matrix alloy is fairly uniform. The wear rate and volume loss showed the two stages (run-in and steady state) of wear for all the applied loads. Microstructural analyses of the wear surfaces and debris were carried out in order to understand the wear mechanism.