Processing maps for optimizing gas atomization and spray deposition

A validated mathematical model was used to generate processing maps for producing near-net shapes of high-performance products by gas atomization and spray deposition. The processing maps are useful to optimize and control the manufacturing process on the shop floor for producing quality products. The number of trial runs and cost of production can be significantly reduced with the help of processing maps. Using a dispersion-strengthened aluminum alloy as an example, this article examines how processing maps can be used to choose a set of process variables for producing the end product of desired quality.