Spray Formed Materials - Plasma Processes


		Spray Formed Materials

Copper alloy combustion chamber liner with a spray formed Inconel 718 structural jacket.

Two Rhenium (top) and Tungsten (bottom) rocket nozzles that were spray formed to net shape on a mandrels

Two Rhenium (top) and Tungsten (bottom) rocket nozzles that were spray formed to net shape on mandrels.

VPS deposition of Tungsten / Rhenium.

Near Net Shape Spray Forming

Near Net Shape Spray Forming is the process used to produce a component or part that is near to the final desired shape. During spray forming, proprietary mandrel processes are used to allow easy removal of the spray formed part. After spray forming, a finishing process may be required to achieve the exact shape and size.

Advantages of near net shape spray forming include, but are not limited to, complex components produced less expensively than machining from large billets, structures can have material properties equivalent to cast or wrought materials, high density components that are helium leak tight, the ability to coat internal and external surface with protective coatings, and the use of multiple materials to produce unique alloys, gradients, bimetallic or metallic/ceramic structures.

Ceramic-Metal
Tungsten-Copper

Ceramic-Metal (left) and Tungsten-Copper
(right) Functional Gradient Coatings

Spray formed beryllium tensile, and conductivity samples Spray formed
beryllium
tensile, and
conductivity
samples

Spray Formed Materials

Metal Alloys Ceramics High Temp Materials

Aluminum
Copper
Steels
Superalloys Alumina
Hafnium Carbide
Hafnium Nitride
Mullite
Tantalum Carbide
Zircon
Zirconia Iridium
Molybdenum
Niobium
Rhenium
Tantalum
Tungsten

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