Two commercial grade aluminum based immiscible bearing alloys were spray-deposited using convergent-divergenttype of nozzle. The processing parameters for spray-deposition were adjusted in such a way that most of the dropletsarrived on the deposition substrate in either liquid or semi-liquid state. The microstructural features of spray-formedand as-cast alloys are compared. In spray-formed alloys equiaxed grains were observed. The cell boundaries andintercellular regions were observed to be decorated with sub-micron sized particles whereas in normal casting thesecond phase was observed to be segregated along grain boundaries. The morphology and distribution of secondphase were observed to have similarity with those in over-spread and atomized powders produced under similarprocessing conditions. The microstructural features observed with variation in spray conditions are discussed indetail.
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