R. J. Adams, Honeywell, Tempe, AZ

Summary:

Honeywell previously introduced Ion Fusion Formation (IFF), a new approach to solid freeform fabrication (SFF) at an earlier AeroMat conference. Additional progress has been made including equipment upgrades, improved automation, improved shielding and the ability to deposit aluminum. We will describe those advances. This is a near-net-shape hardware manufacturing process that uses a very hot ionized gas to deposit metal in small discreet amounts and ultimately build a complete part. Components can be used as-deposited or post-deposition processed to gain some improvement in properties and then final machined. The process has low initial capital, maintenance and operating cost and is user friendly.

SFF was developed as part of the trend toward use of net-shape and near-net-shape methods using no molds, mandrels or patterns such as powder metallurgy, plasma spraying and chemical vapor deposition processes. Using SFF, the part is built in three-dimensional space using a computer and electronic model to direct location of discreet deposits until a full part is built.

Other forms of SFF use expensive lasers for their heat source. IFF uses inexpensive electrical energy to generate power for fusion. Thus the energy can be infinitely varied so a larger range of component size can be fabricated with the same equipment. This can significantly lower the cost of small volume lots.

Previously we presented mechanical properties for low alloy steels and 347 stainless steel. This year we will present results regarding light alloy deposition, superalloy deposition and deposition of other high-temperature materials including their properties. In addition, we will review the requirements for shielding and its effect on properties. Finally progress in component manufacture will be discussed.