Application of Ion Fusion Formation to Refurbishment of Aircraft

Today Aerospace hardware designed decades ago is still in active service and in some cases subject to severe operating conditions. Thus aircraft sustainment is a critical issue and significant challenge. The B-52 first produced in the 1950's is an excellent example. Since the original hardware was designed and put into service, new processing techniques and new design methodology have come into widespread use that were not readily available, if available at all, at the time of the original design. In some cases the original fabricator is no longer in business. As we refurbish older aircraft it is important to use the most efficient and effective techniques available today to get cost effective high performance hardware and aircraft. Honeywell has developed and/or is exploring several new repair/manufacturing techniques that complement each other. For example three complementary techniques are the hand held laser (HHL) for very small repairs, Ion Fusion Formation (IFF) for small to large build-ups and cold spray for large area coverage. This paper will address IFF.