Application of mathematical simulation and the factorial design method to the optimization of the atomization stage in the spray forming of a Cu–6% Zn alloy

Process parameters optimization for the spray forming of a Cu–6% Zn alloy was developed by a combination of mathematical simulation and the factorial design method (FDM). The finite difference method was used for the mathematical simulation of the atomization stage and two levels FDM was applied considering the initial gas velocity, the axial distance between the atomizer and the substrate, the superheating of the melt and the melt flow rate. The validation of the optimized process parameters was done by processing the Cu–Zn alloy, a high-density deposit, as high as 98.5% of the theoretical density with a very homogeneous microstructure being produced.