M3:2 high-speed steel (HSS) billets with or without Nb addition were prepared by spray deposition. The effects of Nb and post-thermal-mechanical processing (decomposition treatment and hot forging), as well as heat treatment, on the microstructure and properties of M3:2 HSS were investigated. The microstructure of the as-deposited M3:2 HSS consisted of equiaxed grains with a mean size of approximately 25 μm and discontinuous plate-like M2C and irregular MC carbides distributed along grain boundaries. 0.5% Nb addition can refine the M2C plates and spheroidize MC carbides. With 2% Nb addition, the refined grains with a mean size of approximately 12 μm and continuous net of M6C and a uniform distribution of NbC carbides were obtained. The decomposition of metastable M2C carbides can be accelerated with 0.5% Nb addition due to the refined size and lower thermodynamic stability of M2C plates. With the increased degree of decomposition of M2C carbide, the M6C and MC carbides became refined and more uniformly distributed after optimal thermal-mechanical processing and heat treatment, which leads to a significant increase in bend strength and toughness.

To determine the spray forming process parameters of 7075/Al–Si bimetallic gradient composite plate with two gas atomizers, a calculation model of the plate has been established by using the finite element software ANSYS. The effects of different motion trajectory, advance speed, swing cycle and spray center distance on shape, and silicon distribution of deposited plate have been simulated by the APDL programming language. The results show that a smooth and uniform surface is obtained when motion trajectory is in a regular jaggies mode. The deposited plate varies from platform to stepped shape with a center distance increasing from 20 mm to 50 mm; meanwhile, the width of the transition zone decreases gradually. As the period increases to 8 s, the silicon distribution of each layer presents a jagged fluctuation. Both the thickness of the deposited plate and the width of the transition zone decrease as the advance speed increases, except the silicon distribution. Finally, the modeling and simulation of the co-spray formed 7075/Al–Si bimetallic gradient composite plate are validated by experimental investigations and the simulation results are in good agreement with the actual results.

As the operating temperature of disk service was elevated from 650 °C to 700 °C, the creep properties urged to be paid attention. To investigate the creep properties of spray-formed low solvus, high refractory (LSHR) superalloy at about 700 °C, creep tests were conducted under seven different stress ranging from 690 MPa to 897 MPa. By means of creep curves and fracture microstructure observation, the creep behaviors and fracture mechanisms of spray-formed LSHR were analyzed. Stress exponent of the alloy was comparable to other disk superalloys such as Waspaloy and Inconel 718. It was interesting to find a transition in the creep behavior in two stress regimes. The contribution of grain boundary sliding in the low stress regime was greater than that in the higher stress. Under higher stress microcracks initiated along the intragranular slip bands because of strain concentration. The spray-forming LSHR exhibited a good creep resistance at low stress compared with other two superalloys by using Larson–Miller parameter, which was consistent with the transition of fracture behaviors.

The microstructural evolution of spray-formed high speed steel during hot deformation was investigated as well as the effects of spray forming parameters on the porosity formation. Four distinct zones are identified in the as-deposited material, and interstitial porosity is present in the bottom and peripheral zones, while gas-related porosity is mainly found in the central zone. It can keep the porosity at a minimum value by using the optimum parameters, e.g., the average porosity of central zone is 3.7% for a superheat of 170 °C and a gas-to-metal flow rate of 0.7. During hot deformation at 1150 °C, the amount of porosity can be obviously decreased by increasing the height reduction which also plays a key role in breaking up eutectic carbides. The critical height reduction for the breakdown of the eutectic carbides is 50%, the dominant mechanism being mechanical fragmentation.