Method of making a metal slab with a non-uniform cross-sectional shape and an associated integrally stiffened metal structure using spray casting

摘要

A method of making a metal slab with a non-uniform cross-sectional shape including providing a spray casting apparatus including a substrate and a plurality of spaced atomization nozzles, the nozzles having a discharge opening and introducing molten metal into the nozzles. The method then includes atomizing the molten metal as it is discharged from the nozzles through the discharge openings by subjecting the discharged molten metal to jets of an atomizing gas in order to form metal droplets for deposition onto the substrate. The deposition of the metal droplets onto the substrate is controlled in order to form the metal slab having a non-uniform cross-sectional shape. A method of making an integrally stiffened metal structure as well as metal and aluminum products made by the above methods are also provided.