A numerical model has been developed to simulate the distribution of polygonal grain size in a sprayed microstructure formed from an alloy droplet spray containing a large number of solid, mushy and liquid droplets. The model takes into account the effects of. (1) the droplet size distribution; (2) its corresponding distribution of solid, mushy and liquid droplets at the instant of deposition; (3) the overall thermal condition of the spray formed preform during final solidification. The model...