Patent GB-925907-A (GB)
Title: Method of producing sprayed metal material
IPC: C23C4/02
Filed: 1960-02-08
Abstract: In a method of producing a sprayed metal sheet-like material made up of flattened metal particles which are interleaved and have all their faces parallel to the surface of the material, the said particles being loaded together by a thermoset loading agent, there are applied to a surface a thermosetting bonding agent and a molten metal sprayed with enough force to cause the molten particles thereof to flatten on impact with the surface, the temperature of the molten metal and the nature of the bonding agent being such that the heat of the metal causes setting of the bonding agent.  The bonding agent and the metal may be applied to the surface alternately or simultaneously.  The process is applied to the production of shaped articles by spraying on to a mould that has been provided with a parting agent and then stripping off the material.  The product may be provided with a sprayed coating of metal or non-metal, e.g. ceramic, by initial application of such material to the mould surface.  A backing of e.g. fibre sheet or cloth impregnated with resin may be applied to the product as a reinforcement to facilitate stripping from the mould. Suitable thermosetting agents are polyester and phenolformaldehyde resins, epoxy resins and other polyglycidyl ether and polyepoxy compounds, ureaformaldehyde and melamine-formaldehyde resins, and aldehyde-amine and ketone-amine resins.  The resin may be applied with a hardener, and may also contain a filler and/or metal powder. The mould, which may be refrigerated during spraying, may be of metal, wood, plaster of Paris, or a synthetic resin.  Specification 589,645 and U.S.A. Specification 2,510,907 are referred to.ALSO:In a method of producing a sprayed metal sheet-like material made up of flattened metal particles which are interleaved and have all their faces parallel to the surface of the material, the said particles being bonded together by a thermoset bonding agent, there are applied to a surface a thermosetting bonding agent and a molten metal sprayed with enough force to cause the molten particles thereof to flatten on impact with the surface, the temperature of the molten metal and the nature of the bonding agent being such that the heat of the metal causing setting of the bonding agent.  The bonding agent and metal may be applied to the surface alternately or simultaneously.  The process is applied to the production of shaped articles by spraying on to a mould that has been provided with a parting agent and then stripping off the material.  The product may be provided with a sprayed coating of metal or non-metal, e.g. ceramic, by initial application of such material to the mould surface.  A backing of e.g. fibre sheet or cloth impregnated with resin may be applied to the product as a reinforcement to facilitate stripping from the mould. The mould may be refrigerated during spraying.  The metal employed in spraying may be iron, steel, bronze, tin, zinc, nickel, brass or copper.  The mould may be of metal, wood, plaster of Paris, or a synthetic resin.  Specification 589,645 and U.S.A.  Specification 2,510,907 are referred to.