What is Spray Forming Material (SFM)
Spray Forming Material is a new casting method for the future. In contrast to conventional casting techniques, spray forming utilizes the atomization of a liquid melt into small droplets by the means of an inert gas. Prior to full solidification, the droplets impinge on a sub-strate to form a billet. The rapid solidification inhibits almost completely any segregation. The microstructure is fine grained and homogeneous with good workability. By injection of particies (see 9. on pic to the below) into the atornizing gas, the possibility exists to create materials which alternatively can only be produced by powder metallurgy techniques. The possabilities with SF1 are endless.

The process steps are as follows:

• Atomikation of the liquid melt into small droplets
• Rapid soffdification of the droplets
• Compaction into a semifinished material.

Does it sound like "high-tech"? It is! But it also creates an enormous platform in the field of increasing quality perfection on existing alloys and in the field of developing new alloys.

Comparison in micro-structure of Copper-Chromium-Zirkonium. Traditional casting (left) and Sprayforming (right)

1. Holding furnace
2. Spout
3. Atomizer
4. Billet
5. Withdrawal unit
6. To dust exhauster
7. Powder collector
8. Spray chamber
9. Particle injector

Advantages - what's the difference in comparison with other casting-rnethods

This method is not profitable in comparison with traditional continous casting of e.g. red brass (Rg 7) or tinbronze (CuSn11 2). The major benefits and advantages are to be found by replacing alloys which today are very costy to manufacture and purchase. Alloys such as Beryllium copper, CopperChromium Zirkonium and Nickel copperalloys, just to mention some alloys.

It is not only the manufacturing cost which differs (through the SFM-method you are able to cast quit small melts to a quite low costs). The SFM-method also automatically produces a material free of tensions. The structure is 100 % homogenous (see pic beside) without any loss in material-abilities. Another advantage is that the material is possible to extrude after it´s been cast, with the possability to reach extra-ordinary high mechanical values.

• Production is made at a proportionate low cost
• Big flexabillty in production
• Size limits today : diameter 0 500 x 2200 mm length (Weight per piece is limited to 2400 kilos/rod today)
• High mechanical values is achieved on SFM-bronze (Eg. Aluminium-bronze with Brinell hardness > 400 HB)
• Proportionately low quantities is needed for a melt. (ca. 200-300 kilos/size)
• Enormous potential - Through the particle injector (see 9. above) we are able to add new substances normally not used, while casting bronze today. E.g. additives of graphite to increase the temperature-range or smaller amounts (<1%) of lead (Pb), increasing the machineability-rate as well as improving the finishing look of the products made.

Through its potential, alloys not excisting today, may be invented, produced and tailor-made acc. to our clients needs and requests. The future is here!

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