Patent ID: 6746225
Filing Date: 2004-06-08
Classification: B22F,B29C,B33Y,C23C

Abstract:
A system for the spray forming manufacture of near net shape molds, dies and related toolings, comprising:a nozzle having a flow channel, said flow channel having an inlet end, an outlet end and a longitudinal axis; a liquid reservoir in fluid communication with said nozzle flow channel, said reservoir adapted to contain a liquid material capable of forming a mold, said liquid being pressurized in a pressurized reservoir and injected from said reservoir through a conduit ending in said nozzle flow channel between said inlet and outlet ends and proximate to said nozzle longitudinal axis; means for flowing a high temperature atomizing gas through the nozzle flow channel from the inlet end to the outlet end at a pressure range of 20 psia to 30 psia to atomize the liquid injected into the flow channel into a plume of atomized droplets; a chamber adapted to contain a quench gas having a controlled temperature and composition for increasing in-flight convection cooling of the atomized droplets thereby enhancing formation of undercooled and partially solidified droplets; means for directing and depositing the undercooled and partially solidified droplets onto a pattern to form the mold.