Patent ID: 7273669

Claim:
A spray formed article, the article comprising: a body comprising a composite spray formed body portion comprising a configuration of particles comprising a first plurality of sprayed metal particles, a second plurality of sprayed metal particles substantially segregate from the first plurality of metal particles, and a pseudo-alloy interposing the first and second plurality of sprayed metal particles, the first plurality of metal particles being composed of a first metal, the second plurality of metal particles being composed of a second metal, different from the first metal, and the pseudo-alloy being composed of the first and second metals, wherein the first metal comprises zinc or zinc- alloy and the second metal comprises a predominantly non-zinc metal, wherein the composite spray formed body portion includes a first surface including a first portion being comprised of the first metal, a second portion being comprised of the second metal and a third portion being comprised of the pseudo-alloy and interposed between the first and the second portions of the first surface, and a second surface opposing the first surface and including a first portion being composed of the first metal and a second portion being comprised of the second metal.