A validated mathematical model was used to generate processing maps fo
r producing near-net shapes of high-performance products by gas atomiz
ation and spray deposition. The processing maps are useful to optimize
and control the manufacturing process on the shop floor for producing
quality products. The number of trial runs and cost of production can
be significantly reduced with the help of processing maps. Using a di
spersion-strengthened aluminum alloy as an example, this article exami
nes alloy as an example, this article examines how processing maps can
be used to choose a set of process variables for producing the end pr
oduct of desired quality.