Patent ID: 8573283

Claim:
A method for producing a material composite comprising a substrate and at least one functional layer made from at least two different materials which are not alloyable by conventional methods, comprising the steps of: melting a first material and a second material, said first material being different from said second material, said first material not being alloyable with said second material by mixing said first material and said second material together in a molten state; spray compacting said first material and said second material onto a surface of a substrate, said spray compacting being performed simultaneously from at least a first nozzle and a second nozzle which respectively spray droplets of said first material and said second material towards said substrate using a spray gas, wherein said spray compacting is performed under conditions which control a temperature of a melt of said first material and a temperature of a melt of said second material, a temperature and a pressure of said spray gas; and producing at least one functional layer on said surface of said substrate from said first material and said second material by allowing droplets of said first material and said second material to intermingle for a short period on said surface of said substrate in a liquid state, and then hardening intermingled droplets of said first material and said second material into said at least one functional layer which is bonded to said surface of substrate and with said first material being alloyed to said second material as one composition.