Sprayed Metal Shells for Tooling: Improving the Mechanical Properties

Tbis work describes methods to improve the quality of the metal resulting from thermal spray deposition, including both the mechanical and metallurgical behavior. The engineering context is the production of sprayed metal shells suitable for tooling applications. The sprayed metal shells are mechanically dominated by interparticle interfaces; the particles are largely mechanically interlocked with very little metallurgical bonding. Based on these observations, improvements are made to these interfaces, and the measure of the improvement is shown in mechanical tests.