Co-Spray Forming of Gradient Deposits from Two Sprays of Different Tool Steels Using Scanning Gas Atomizers



A co-spray forming process was developed to produce gradient deposits from two sprays of different tool steels using scanning gas atomizers. The tool steel melts were atomized and co-sprayed simultaneously onto a horizontally moving flat substrate, resulting in a flat deposit with a gradient zone between two layers of the different steels when the two sprays were overlapped. The gradient deposits were investigated with respect to the porosity, element distributions, microstructure, and hardness. It showed that a sound deposit with a desired gradient zone could be achieved under proper processing conditions.