Patent ID: 6883581

Claim:
A method for implementing post-heat treatment during spray forming to achieve stress control in the manufacture of a spray formed metallic tool, comprising: applying a metallic spray-forming material at a preselected application temperature upon a mold substrate heated to a preselected substrate temperature disposed within a spray forming cell environment heated to a preselected spray forming cell environment temperature in the manufacture of a spray-formed tool; causing preselected substantially homogenous metallic phase transformations from an austenite phase of the spray forming material to a substantially homogenous distribution of commingled metallic phases consisting of a predetermined proportion of at least one of a bainite phase, a pearlite-ferrite phase, and a martensite phase of the spray forming material; and wherein the substantially homogenous metallic phase transformations are caused at least in part via manipulation of at least one of the substrate temperature and the spray forming cell environment temperature.