This invention relates to the production of metal or metal alloy spray deposits using an oscillating spray for forming products such as tubes of semi-continuous or continuous length or for producing tubular, roll, ring, cone or other axi-sym e ric shaped deposits of discrete length. The invention also relates to the production of coated products.

Methods and apparatus are known (our UK Patent Nos : 1379261, 1472939 and 1599392) for manufacturing spray- deposited shapes of metal or metal alloy. In these known methods a stream of molten metal, or metal alloy, which teems from a hole in the base of a tundish, is atomised by means of high velocity jets of relatively cold gas and the resultant spray of atomised particles is directed onto a substrate or collecti g surface to form a coheren deposit. In these prior methods it is also disclosed Chat by extracting a controlled amount of heat from the atomised particles in flight and on deposition, it is possible to produce a spray-deposit hich is no -ρarticulate in nature, over 95. dense and possesses a substantially uniformly distributed, closed to atmosphere pore structure. present produces, s ch as tubes for example, are produced by the gas atomisacior. of a stream of molten metal nd by directi the resultant spray o o a

rotating, tubular shaped substrate. The rotating substrate can either traverse slowly through the spray to produce a long tube in a single pass or may reciprocate under the spray along its axis of rotation (as disclosed in our UK Patent So: 1599392) to produce a tubular deposit of a discrete length. By means of the first method (termed the single pass technique) the metal is deposited in one pass only. In the second _ι method (termed the reciprocation technique) the metal is deposited in a series of layers which relate to the number of reciprocations under the spray of atomised metal. In both these prior methods the spray is of fixed shape and is fixed in position (i.e. the mass flux density distribution of particles is effectively constant with respect to time) and this can result in problems with respect to both production rate and also metallurgical quality in the resulting spray deposits.

These problems with regard to the single pass technique are best understood by referring to Figure 1 and Figure 2. The shape of a spray of atomised molten metal and the mass distribution of metal particles in the spray are mainly a function of the type and specific design of the atomiser used and the gas pressure ur.de- which it operates. Typically, however, a spray is co l in sf.ape with a nigh ensity of particles ::. c.-.e ce tre i.e. towarαs tne mea axis of he spr y X a d a low density at its periphery. The "deposition profile"

of the deposit D which is produced on a tubular-shaped substrate 1 which is rotating only under this type of spray is shown in Figure 1(a). It can be seen that the thickness of the resulting deposit D (and consequently the rate of metal deposition) varies considerably from a position corresponding to the central axis X of the spray to its edge. Figure 1(b) shows a section through a tubular spray deposit D formed by traversing a rotating tubular-shaped collector 1 through the same spray as in Figure 1(a) in a single pass in the direction of the arrow to produce a tube of relatively long le gth. Such a method has several major disadvantages. For example, the inner and outer surface of the spray-deposited tube are formed from particles at the edge of the spray which are deposited at relatively low rates of deposition. A low rate of deposition allows the already deposited metal to cool excessively as the relatively cold atomising gas flows over the deposition surface. Consequently, subsequently arriving particles do not "bond" effectively with the already deposited metal resulting in porous layers of i tercon ected porosity at the i ner and outer surfaces of the deposit. This interco nected porosity hich connects to the surface of the deposit ca suffer inter al xidation on removal of the deposit from tne protecti e atmosphere i side the spray c amber. In total these porous la ers c n accou t for up to 15. of

the total deposit thickness. The machining off of these porous layers can adversely affect the economics of the spray deposition process. The central portion of the deposit is formed at much higher rates of particle deposition with much smaller time intervals between the deposition of successive particles. Consequently, the deposition surface is cooled less and the density of the deposit is increased, any porosity that does exist is in the form of isolated pores and is not interconnected.

The maximum overall rate of metal deposition (i.e. production rate) that can be achieved (for a given atomiser and atomising gas consumption) in the single pass technique is related to the maximum rate of deposition at the centre of the spray. If this exceeds a certain critical level insufficient heat is extracted by the atomising gas from the particles in flight and on deposition, resulting in an excessively high liquid metal content at the surface of the already deposited metal. If this occurs the liquid metal is deformed by the atomising gas as it impinges on the deposition surface and can also be ejected from the surface of the preform by the centrifugal force generated from the rotation of the collector. Furthermore, casting type detects (e.g. shrinkage porosity, hot tearing, etc.) can occur in the de.osi .

A further problem with the single pass technique the prior art is that the deposition surface has a lo angle of inclination relative to the direction of the impinging particles (as shown in Figure 1(b)) i.e. th particles impinge the deposition surface at an obliqu angle. Such a low impingement angle is not desirable and can lead to porosity in the spray deposit. This caused by the top parts of the deposition surface act as a screen or a barrier preventing particles from be deposited lower down. As the deposit increases in thickness particularly as the angle of impingement becomes less than 45 degrees, the problem becomes progressively worse. This phenomenon is well known fr conventional metallising theory where an angle of impingement of particles relative to the deposition surface of less than 45 degrees is very undesirable a can result in porous zones in the spray deposit. Consequently, using the single pass technique there i limit on the thickness of deposit that can be successfully produced. Typically, this is approxima 50mm wall thickness for a tubular shaped deposit.

The three major problems associated with the si pass technique; namely, surface porosity, limited met deposition rate and limited wall thickness can be pa o erco e y usi g reciproc io tecr.r.ique w ere _e:ai is deposited in a series of iayers y traversi the rotating collector backwards and forwards under

spray. However, where, reciprocation movements are required there is a practical limit to the speed of movement particularly with large tubular shaped deposits (e.g. 500kg) due to the deceleration and acceleration forces generated at the end of each reciprocation stroke. There is also a limit to the length of tube that can be produced as a result of an increasing time interval (and therefore increased cooling of the deposited metal) between the deposition of each successive layer of metal with increasing tube length. Moreover, the micros tructure of the spray deposit often exhibits "reciprocation bands or lines" which correspond to each reciprocation pass under the spray. Depending on the conditions of deposition the reciprocation bands can consist of fine porosity and/or micros ructural variations in the sprayed deposit corresponding to the boundary of two successively deposited layers of metal; i.e. where the already deposited metal has cooled excessively mainly by the atomising gas flowing over its surface prior to returning to the spray on the next reciprocation of the substrate. Typically the reciprocation cycle would be of the order of 1-10 seconds depending on the size of the spray-deposited article .

The problems associated vita Doth the single pass technique and the reciprocatio technique can be

substantially overcome by utilising the present invention .

According to the present invention there is provided a method of forming a deposit on the surface of a substrate comprising the steps of; generating a spray of gas atomised molten metal, metal alloy or molten ceramic particles which are directed at the substrate, rotating the substrate about an axis of the subs trate , extracting heat in flight and/or o deposition from the atomised particles to produce a coherent deposit, and oscillating the spray so that the spray is moved over at least a part of the surface of the substrate.

The atomising gas is typically an inert gas such as Nitrogen, Oxygen or Helium. Other gases, however, can also be used including mixed gases which may contain Hydrogen, Carbon Dioxide, Carbon Monoxide or Oxygen. The atomising gas is normally relatively cold compared to the stream of liquid metal.

The present invention is particularly applicable to the contino-us production of tubes, or coated tubes or coated bar nd in this arrangement the substrate is in the form of a tube or solid bar hich is rotated ar._ tra ersed in n axial directio i a single pass ar.fe: the oscillating spra . in this arrangement the

oscillation, in the direction of movement of the substrate has several important advantages over the existing method using a fixed spray. These can be explained by reference to Figures 2(a) and 2(b). The "deposition profile" of the deposit which is produced on a tubular shaped collector which is rotating only under the oscillating spray is shown in Figure 2(a). By comparing with Figure 1(a) which is produced from a fixed spray (of the same basic shape as the oscillating spray) it can be seen that the action of oscillating the spray has produced a deposit which is more uniform in thickness. Figure 2(b) shows a section through a tubular sprayed deposit formed by traversing in a single pass a rotating tubular shaped collector through the oscillating spray. The advantages of an oscillating spray are apparent and are as follows (compare Figures 1 and 2):

(i) Assuming that there is no variation in the speed of movement of the spray within each oscillation cycle the majority of metal will be deposited at the same rate of deposition and therefore the conditions of deposition are relatively uniform. The maximum rate of metal deposition is also lower-when compared to he fixed spray of Figure 1(a) which means that the overall depositio rate r. _e increase! without the Gep-._ti.-. surface becoming excessively hot (or containing an excessively hi h liquid content).

(ii) The percentage of metal at the leading and trailing edges of the spray which is deposited at a low rate of deposition is markedly reduced and therefore the amount of interconnected porosity at the inner and outer surface of the spray deposited tube is markedly reduced or eliminated altogether.

(iii) For a given deposit thickness the angle of impingement of the depositing particles relative to the deposition surface is considerably higher. Consequently much thicker deposits can be successfully produced using an oscillating spray.

It should be noted that simply by increasing the amplitude of oscillation of the spray (within limits e.g. included angles of oscillation up to 90° can be used) the angle of impingement of the particles at the deposition surface can be favourably influenced and therefore thicker deposits can be produced. In addition, for a given deposit, an increased amplitude also allows deposition rates to be increased, (or gas consumption to be decreased). Therefore, the economics and the production output of the spray deposition process can be increased.

The present invention is also applicable to the production of a sprayed deposit of discrete length where there is no axial mo ement of the substrate, i.e. :„e substrate rotates only. A "discrete len th deposit" is typically a single product of relatively short

length, i.e. typically less than 2 metres long. For a given spray height (the distance from the atomising zone to the deposition surface) the length of the deposit formed will be a function of the amplitude of oscillation of the spray. The discrete deposit may be a tube, ring, cone or any other axi-symmetric shape. For example, in the formation of a tubular deposit the spray is oscillated relative to a rotating tubular shaped collector so that by rapidly oscillating the spray along the longitudinal axis of the collector being the axis of rotation, a deposit is built up whose microstructure and properties are substantially uniform.

The reason for this is that a spray, because of its low inertia, can be oscillated very rapidly (typically in excess of 10 cycles per second i.e. at least 10-100 times greater than the practical limit for reciprocating the collector) and consequently reciprocation lines which are formed in the reciprocation technique using a fixed spray are effectively eliminated or markedly reduced using this new method.

By controlling the rate and amplitude of oscillation and the instantaneous speed of movement of the spray throughout each oscillation cycle it is possible to form the deposit under whatever conditions are required to ensure uniform deposition conditions and therefore a uniform rr.icrostructure a a co t olled shape. A simple deposition profile is sh wn in

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Figure 2(a) but this can be varied to suit the alloy and the product. In Figure 2(a) most of the metal has been deposited at the same rate of deposition.

The invention can also be applied to the production of spray-coated tube or bar for either single pass or discrete length production. In this case the substrate (a bar or tube) is not removed after the deposition operation but remains part of the final product. It should be noted that the bar need not necessarily be cylindrical in section and could for example be square, rectangular, or oval etc.

The invention will now be further described by way of example with reference to the accompanying diagrammatic drawings in Figures 3-9.

Figure 3 illustrates the continuous formation of a tubular deposit in accordance with the present invention ;

Figure 4 is a photomicrograph of the micros rueture of a nickel-based superalloy IN625 spray deposited in conventional manner with a fixed spray on to a mild steel collector ;

Figure 5 is a photomicrograph of the microstrueture of IN'625 spray deposited by a single pass technique in accordance with the invention onto a mild steel collector ;

Figure ό illustrates a i _ _ ~ _ _-r. - Z i z - L _ y the for- ioπ of a discrete tubular deoosit.

Figure 7 illustrates the formation of a discrete tubular deposit of substantially frus to-conical shape;

Figure 8 illustrates diagra matically a method for oscillating the spray; and

Figure 9 is a diagrammatic view of the deposit formed in accordance with the example discussed later.

In the apparatus shown in Figure 3 a collector 1 is rotated about an axis of rotation 2 and is withdrawn in a direction indicated by arrow A beneath a gas atomised spray 4 of molten metal or metal alloy. The spray.4 is oscilliated to either side of a mean spray axis 5 in the direction of the axis of rotation of the substrate 1 - which in fact coincides 'with the direction of withdrawal .

Figures 4 and 5 contrast the micros tructures of an IN625 deposit formed on a mild steel collector in the conventional manner (Figure 4) and in accordance with the invention (Figure 5) on a single continuous pass under an oscillating spray. The darker portion at the bottom of each photomicrograph is the mild steel collector, and the lighter portion towards -the top of each photomicrograph is the spray deposited I 625. In Figure 4 there are substantial areas in the spray deposited IN'625 which are black and which are areas of rosit . In. Figure 5 usi the oscillati spray

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technique of the invention the porosity is subs antially eliminated .

In Figure 6 a spray of atomised metal or metal alloy droplets 11 is directed onto a collector 12 which is rotatable about an axis of rotation 13. The spray deposit 14 builds up on the collector 12 and uniformity is achieved by oscillating the spray 11 in the direction of the axis of rotation 13. The speed of oscillation should be sufficiently rapid and the heat extraction controlled so that a thin layer of semi-solid/semi- liquid metal is maintained at the surface of the deposit over its complete length. For example, the oscillation is typically 5 to 30 cycles per second.

As seen from Figure 7 the shape of the deposit may be altered by varying the speed of movement of the spray within each cycle of oscillation. Accordingly, where the deposit is thicker at 15 the speed of movement of the spray at that point may be slowed so that more metal is deposited as opposed to the thinner end where the speed of movement is increased. In a similar manner shapes can also be generated by spraying onto a collector surface that itself is concical in shape. More complicated shapes can also be generated by careful control of the oscillating amplitude and instantaneous speed of mo eten within each cycle of oscillation. It is also possi le to a y the gas to etal ratio durin each c cle of oscillation in order to accuratelv control

the cooling conditions of the atomised particles deposited on different part of the collector. Furthermore the axis of rotation of the substrate need not necessarily be at right angles to the mean axis of the oscillating spray and can be tilted relative to the spray .

In one method of the invention the oscillation of the spray is suitably achieved by the use of apparatus disclosed diagrammatically in Figure 8. In Figure 8 a liquid stream 21 of molten metal or metal alloy is teemed through an atomising device 22. The device 22 is generally annular in shape and Is supported by diametrically projecting supports 23. The supports 23 also serve to supply atomising gas to the atomising device in order to atomise the stream 21 into a spray 24. In order to impart movement to the spray 24 the projecting supports 23 are mounted in bearings (not shown) so that the whole atomising device 22 is able to tilt about the axis defined by the projecting supports 23. The control of the tilting of the atomising device 22 comprises an eccentric cam 25 and a cam follower 26 connected to one of the supports 23. By altering the speed of rotation of the cam 25 the rate of oscillation of the atomising device 22 can, be varied. In addition, by changing the surface profile of the cam 25, the speed of τ.ovener.t of cne spray at any instant during the cyle of oscillator, can be varied. In a preferred method of

the invention the movement of the atomiser is controlled by electro-mechanical means such as a programme controlled stepper motor, or hydraulic means such as a programme controlled electro-hydraulic servo mechanism.

In the atomisation of metal in accordance with the invention the collector or the atomiser could be tilted. The important aspect of the invention is that the spray is moved over at least a part of the length of the collector so that the high density part of the spray is moved too and fro across the deposition surface. Preferably, the oscillation is such that the spray actually moves along the length of the collector, which (as shown) is preferably perpendicular to the spray at the centre of its cycle of oscillation. The spray need not oscillate about the central axis of the atomiser, this will depend upon the nature and shape of the deposit being formed.

Full detailsof the preferred apparatus may be obtained from our co-pending application filing herewith to which reference is directed.

The speed of rotation of the substrate and the rate of oscillation of the spray are important parameters and it is essential that they are selected so that the metal is deposited uniformly during each revolution of the collector. Knowing the mass flux density distribution of the spray transverse to the direction of oscillation it is possible to calculate the number of

spray oscillation per revolution of the substrate which are required for uniformity.

One example of a discrete length tubular product is now disclosed by way of example:

EXAMPLE OF DISCRETE LENGTH: TUBULAR PRODUCT

DEPOSITED MATERIAL - 2.5% Carbon, 4.3% Chromium, 6.3% Molybdenum, 7.3% Vanadium, 3.3% Tungsten, 0.75% Cobalt, 0.8% Silicon, 0.35% Manganese, Balance Iron plus trace elements

POURING TEMP. - 1450 degrees C

METAL POURING NOZZLE - 4.8mm diameter orifice

SPRAY HEIGHT - 480mm (Distance from the underside of the atomiser to the top surface of the collector )

OSCILLATING ANGLE -- -+ ^• /- 9 degrees about a vertical axis

OSCILLATING SPEED - 12 c cles,'sec

AlϋMISING GAS - itrogen at ambie t temperature

COLLECTOR - 70mm outside diameter by lmm wall thickness stainless steel tube (at ambient temperature) COLLECTOR ROTATION - 95 r.p.m.

LIQUID METAL FLOW RATE

INTO ATOMISER - 18kg/min

GAS/METAL RATIO - 0.5-0.7 kg/kg

Note that this was deliberately varied throughout the deposition cycle to compensate for excessive cooling by the cold collector of the first metal to be deposited and to maintain uniform deposition conditions as the deposit increases in thickness.

DEPOSIT SIZE - 90mm ID 170mm 0D 110mm long

The average density of the deposit in the above example was 99.8% with essentially a uniform microstructure and uniform distribution of porosity throughout the thickness of the deposit. A similar tube made under the same conditions except that the collector was oscillated under a fixed spray at a rate of 1 cycle per 2 seconds, showed an average density of 98.7%. In addition, the porosity was mainly present of the reciproca ion lines and not uniformly distributed. The grain structure and size of carbide precipitates were also variable being considerably finer in the

reciprocation zones. This was not the case with the above example where the micros ructure was uniform throughout.

There is now disclosed a second example of a deposit made by the single pass technique and with reference to Figures 4 and 5 discussed above:

EXAMPLE OF DEPOSIT MADE BY THE SINGLE PASS TECHNIQUE

FIXED SPRAY OSCILLATING SPRAY DEPOSITED MATERIAL IN625 IN625

POURING TEMPERATURE 1450°C 1450°C

METAL POURING NOZZLE

(ORIFICE DIAMETER) 6.8mm 7.6mm

SPRAY HEIGHT 380mm 380mm

OSCILLATING ANGLE 0 3 ^β about vertical axis OSCILLATING SPEED 0. 25 cycles per second ATOMISING GAS Nitrogen Nitrogen

COLLECTOR 80mm diameter stainless steel by lmm wall thickness COLLECTOR ROTATION 3 r.p.s. 3 r.p.s.

TRAVERSE SPEED OF

COLLECTOR 0.39 m/min 0.51 m/min

LIQUID METAL FLOW

RATE INTO ATOMISER 32 fcg/min 42 kg/rain

GAS/METAL RATIO 0.5 kg/kg 0.38 kg/kg

SIZE OF DEPOSIT SOrara ID by 130mm OD

POROSITY See Fig. 4 See Fig. 5

It will be noted from Figure 5 that there is reduced porosity for the Oscillating Spray. Also a higher flow rate of metal and a lower gas/metal ratio has been achieved.

In the method of the invention it is essential that, on average, a controlled amount of heat is extracted from the atomised particles in flight and on deposition including the superheat and a significant proportion of the latent heat.

The heat extraction from the atomised droplets before and after deposition occurs in 3 main stages:- (i) in-flight cooling mainly by convective heat transfer to the atomising gas. Cooling will typically be in the range 10-3 - 10-6 degC/sec depending mainly on the size of the atomised particles. (Typically atomised particles sizes are in the size range 1-500 microns);

(ii) on deposition, cooling both by convection to the atomising gas as it flows over the surface of the spray deposit and also by conduction to the already deposited metal; and

(iii) after deposition cooling by conduction to the already deposited metal.

It is essential to carefully control the heat e raction in each of the three above stages. It is also important to ensure that the surface of the already deposited metal consists of a layer of semi~solid/semi-

liquid metal into which newly arriving atomised particles are deposited. This is achieved by extracting heat from the atomised particles by supplying gas to the atomising device under carefully controlled conditions of flow, pressure, temperature and gas to metal mass ratio and also by controlling the further extraction of heat after deposition. By using this technique deposits can be produced which have a non-particulate microstructure (i.e. the boundaries of atomised particles do not show in the micros ructure) and which are free from macro-segregation.

If desired the rate of the conduction of heat on and after deposition may be increased by applying cold injected particles as disclosed in our European Patent published under No: 0198613

As indicated above the invention is not only applicable to the formation of new products on a substrate but the invention may be used to form coated products. In such a case it is preferable that a substrate, which is to be coated is preheated in order to promote a metallurgical bond at the substrate/deposi interface. Moreover, when forming discrete deposits, the invention has the advantage that the atomising conditions can be varied to give subs antially uniform deposition conditions as the deposit increases in thickness. For example, any cooling of the first metal particles to be deposited on the collector can be

reduced by depositing the initial particles with a low gas to metal mass ratio. Subsequent particles are deposited with an increased gas to metal mass ratio to maintain constant deposition conditions and therefor, uniform solidification conditions with uniform microstructure throughout the thickness of the deposit.

It will be understood that, whilst the invention has been described with reference to metal and metal alloy deposition, metal matrix composites can also ^' be produced by incorporating metallic and/or non-metallic particles and/or fibres into the atomised spray. In the discrete method of production it is also possible to produce graded microstructures by varying the amount of particles and/or fibres injected throughout the deposition cycle. The alloy composition can also be varied throughout the deposition cycle to produce a graded microstructure. This is particularly useful for products where different properties are required on the outer surface of the deposit compared to the interior (e.g. an abrasion resistant outer layer with a ductile main body). In addition, the invention can also be applied to the spray-deposition of non-metals, e.g. molten ceramics or refractory materials.