Many metal processing techniques are dictated by equilibrium thermodynamics and the kinetics of phase transformation. Consequently, an alloy of a specific chemical composition must be processed in a unique manner to obtain the desired postprocessing microstructure and, therefore, the properties. In this respect conventional processes are coupled; any change in any one process variable and/or the chemical composition affects all the properties of the metal part. This limitation can be eliminated by using orthonormal processing techniques which allow the uncoupling of processing and properties. Examples of Orthonormal Metal Processing (OMP) techniques are given in this paper. A newly developed process comprises the impingement of two or more streams of liquid metal components (which mix due to turbulent eddies) and freezing the liquid mixture rapidly. This process can create a variety of microstructures of various metal compositions. Part 1 of this paper describes the concept and theory. Part 2 presents the experimental results.

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