Normally particle injection in spray forming is used to produce metal matrix composites. The injection of overspray powder, which is always generated during the conventional process, could lead to a higher overall material yield and in that manner to a more economical process. But besides economical reasons the high material quality of spray formed products must remain at least constant. It is known in theory that the material quality depends on the thermal conditions in the process, which is affected by the "cold" injected particles. The cold mass of material affects the amount of liquid melt in the spray that is needed for a good deposition. Therefore, the process parameters have to be adjusted to get higher yield and enhanced material properties. The results show the connection between process parameters, yield, porosity, grain size, and segregation:
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