A three-dimensional model has been formulated to calculate the shape of the general preform, using vector calculus. The shape of a rod, tube, plate, or irregular preform can be calculated at given spray forming conditions. The shape of a spray-formed rod was analyzed at various spray forming conditions using the three-dimensional model. The effects of spray forming parameters, such as spray distribution parameters, angular velocity of rotation, withdrawal velocity, spray angle, and eccentric distance on rod shape, were analyzed. The most important parameters affecting the shape of rods are the spray distribution parameters and the withdrawal velocity. The dynamic evolution of rod shape with a stepwise variation of the withdrawal velocity during spray forming was investigated. The effect of a stepwise change of the withdrawal velocity was the same as that of the scanning atomizer. The calculated surface profiles were compared with those of spray-formed 7075 aluminum alloy rods prepared on a pilot scale. The calculated results for the surface profiles were in agreement with those of the spray-formed rods.

A methodology to control interfacial microstructures, while suppressing formation of Al 4 C 3 in wrought Al alloy composites reinforced with SiC, was demonstrated. Thermodynamic calculations were carried out to elucidate how one can select process parameters in terms of alloy composition and fabrication temperature to obtain intended interfaces. Experimental verifications were conducted using scanning electron microscopy (SEM) and transmission electron microscopy (TEM) to validate calculated results. The reaction mechanisms for forming various interfaces were identified both theoretically and experimentally. Evaluations of the interfacial bonding strengths and interfacial stability at elevated temperatures were also carried out for various interface types.

The joining characteristics of oxidized SiC particles with Al–Mg alloy during reaction infiltration processing for fabrication of the composite were studied. From the measurement of weight changes due to the transformation from SiC into SiO2, it became clear that the thickness of SiO2 layer which was formed at the surface of SiC particles increased parabolically with holding time at the given exposing temperatures. The degree of oxidation of the preform made by SiC particles can be controlled by the application of the present oxidation data. The microstructure observed by field emission scanning electron microscopy showed network skeleton via necklike oxidized-joining among the SiC particles and the compressive strength of the perform increased with oxidation temperature. Furthermore, the microstructure of the composite which was fabricated by Al–2 wt% Mg alloy via reaction infiltration processing was examined and the formation of spinel was observed to join the matrix with the particles like a bridge, which is suitable to make the complicate and strong preforms for the near net-shape composites application in electronic packaging.

Interfacial reactions in the squeeze-cast SAE 329 Al alloy reinforced with SAFFIL and carbon fibers were investigated using scanning and transmission electron microscopy and secondary ion mass spectroscopy. The SiO 2 layer added as a binder for the preform of SAFFIL fiber appeared to prevent excessive reaction between the fiber and the molten Al alloy during casting. In the as-cast composite, the reaction between the SiO 2 layer and the Al alloy is considered to produce MgO crystals in the vicinity of SAFFIL fiber. With subsequent heat treatment of the composite to the T6 condition, small crystals of MgO and MgAl 2 O 4 were found to form at the surface of SAFFIL fiber as a result of interfacial reaction between the SiO 2 layer and the Al alloy. Even at the T6 condition, significant reactions between the Al alloy and SAFFIL fiber itself were not observed, indicating the effective role of the binder layer in suppressing the degradation of SAFFIL fiber by reaction with the Al alloy.

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