The spray droplets were deposited over a rotating copper substrate
to achieve a disc shape preform. The thickness uniformity of the
preform was found to depend on the preform distance from the
nozzle, preform offset distance from the axis of the atomizer and
inclination of the preform from the horizontal plane. Mathematical
equations were developed to represent the thickness variation of
the preform with aforementioned parameters. The porosity, hardness,
strength, wear and microstructural studies of the Al-Si-Pb spray
deposited alloys were conducted for different lead content, top to
bottom distance of the deposit and the distance from centre to
periphery of the deposit. Overspray and worn debris particles were
also analyzed. Particles/droplets of two different types were
observed to deposit on the substrate. First type particles were
aluminum rich and second type were lead rich.
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