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Tuesday, June 9, 2009 - 10:30 AM
LAT1.4

Advances in Ion Fusion Formation (IFF): An Alternative Solid Freeform Fabrication Process

R. J. Adams, Honeywell, Tempe, AZ

Honeywell continues to make steady progress with its entry into the Solid Free-form Fabrication manufacturing technology called Ion Fusion Formation (IFF), a Direct Metal Deposition (DMD) process. These direct metal deposition processes are also called additive manufacturing (AM). New advances have been made including equipment upgrades to extend the size range, new materials deposition capability and improved shielding. Furthermore, we have begun efforts to develop tooling manufacture & repair capability. 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. The latter condition can give some improvement in properties for heat treatable materials just as conventional casting or forging heat treatable alloys currently undergo a final heat treatment for property improvement. The process has low initial capital, maintenance and operating cost and is user friendly.

Discussion of IFF capabilities will include efforts to improve surface finish, deposit new materials and improve properties. IFF efforts have been directed to build structures with commercially available materials i.e. existing castings or forging materials. Our most recent materials advances are with Al alloys and Ti 6-4 but many other materials have been studied. The properties of IFF deposits meet or exceed the conventional materials & therefore can be used as direct substitutes.  Thus the entry of IFF into the manufacturing base can be facilitated by using the same materials as more conventional processes.

We will present mechanical properties for tooling materials as well as low alloy steels, stainless steel, titanium, aluminum alloys and high-temperature materials including their properties.  In addition, we will review the requirements for shielding and its effect on properties as well progress in component manufacture will be discussed.


Summary: IFF is an addtive manufacturing process in which important improvemnts have been made to facilitate entry in to the market. Those imrovements will be discussed in the subject presentation.