Spray forming is suitable for preparation of Al or Cu- based alloys and composite. Please go through the articles on the following google links. They contains a package of scientific and practical knowledge . I hope this helps you.
Spray forming is not suitable for aluminum except in a neutral environment. As you know, aluminum is so reactive, specially with oxygen. Except you want to produce a aluminum-alumina composite with a special array. But in copper neutral environment can be better but not required.
Spray forming is a process that is suited well for many alloys, including Fe-, Cu-, Al-, Sn-, Co and Ni alloys. It is a volume production, and not coating process, and is commercially performed for Al- and Cu alloys as well as steels at flowrates of 1t/hour and more. To avoid oxidation, spray forming is always carried out in an inert atmosphere, so that the spray formed deposit will usually not contain a significant number of oxides (unless wanted for in-situ MMC).
But: Spray forming is not an easy process. It requires knowledge about the atomization of metallic melts, their deposition and many other processing aspects. So this is nothing you would setup as a friday afternoon job :-)
Please let me know if you need further information on spray forming - we are running several spray forming plants and you can also find some literature in my account. Do not hesitate to ask!