A novel technique of rapid solidification net- form materials synthesis

A novel method of net-form materials synthesis that is related to spray forming has been conceived, and initial verification experiments have been successfully completed. The method uses streams of ultra-uni-form droplets of molten metal that are deposited onto a substrate in a controlled environment. The drop-lets are directed onto the substrate with measured angular dispersions as small as 2 × 10^-6 radians, and speed dispersions as small as 3.5 × 10^-7 times the average speed of the droplet, thereby facilitating the synthesis of small, detailed parts as well as large bulk parts with high resolution and a uniformly fine grain structure.