droplets strike the substrate whilst in the semi-solid condition; this provides sufficient liquid fraction to "stick" the solid fraction together. Deposition continues, gradually building up a spray-formed billet of metal on the substrate.

The gas atomised spray forming (GASF) process typically has a molten alloy flow rate of 1-20 kg/min, although twin-atomizer systems can achieve metal flow rates of up to 80 kg/min. Special steel billets of 1 tonne or more have been produced