Developing and transitioning groundbreaking

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1 Navy Metalworking Center Cuts Costs through Innovative Technology Dianne Frye DeLisa Navy Metalworking Center Johnstown, Pa. The U.S. Navy ManTech Program aims to implement viable advanced manufacturing technology solutions that meet Navy needs while maximizing the financial return on investment. Developing and transitioning groundbreaking manufacturing solutions is key to achieving the U.S. Navy s budget goals. In his 2011 guidance, Chief of Naval Operations Admiral Gary Roughead said that as we continue to protect our country s interests around the globe, there is an increasing demand for naval forces. Meeting that demand through affordable acquisition and maintenance of the fleet has never been more critical. There are great challenges today, but in every challenge there are opportunities to seek innovative approaches and take bold action. There is no option; the Navy will work more efficiently in our resource-constrained environment, Admiral Roughead wrote. The Office of Naval Research s (ONR) Manufacturing Technology (ManTech) program works directly toward that end it develops and transitions advanced manufacturing solutions to improve the U.S. Navy fleet s affordability and mission capability. ONR funds Centers of Excellence (COEs), which carry out projects within their individual areas of technical expertise; e.g., metalworking, composites, and electronics. The COEs work cooperatively with industry, academia, and the Naval Research Enterprise to develop improved processes, materials, and equipment. A current Navy Metalworking Center project is developing a flame-brazing system to replace manual brazing of pipe fittings on aircraft carriers and submarines. The alternative system is expected to save the Navy $1.9 million in the construction of three CVN and six VCS hulls. Courtesy of NMC. Advanced metalworking and manufacturing technologies One of the COEs, the Navy Metalworking Center (NMC), has a strong track record of successfully developing advanced metalworking and manufacturing technologies, materials, and related processes. NMC has been operated since 1988 by Concurrent Technologies Corp. (CTC), which assists both government and commercial clients with a wide variety of expertise including advanced materials, manufacturing, and engineering; environment and sustainability; learning and human performance; information technology solutions; and many others. For example, CTC was the primary contractor on the successful Carriage, Stream, Tow, and Recovery (CSTRS) program for the Navy s MH-60S helicopter, from system design through manufacture. CTC is also a national leader in friction stir welding (FSW) technology, performing significant Army- and Navy-funded work, and advancing the state of FSW technology for military applications. NMC s expertise centers on metalworking and joining technologies, shipyard processes, advanced metallic materials, design for manufacturing, and coatings application and removal. The Navy Metalworking Center is steadfastly committed to meeting the Navy s evolving needs, which is increasingly focused on affordability. Our successes in developing innovative metalworking and manufacturing solutions are the result of our focus on teamwork, dedication and technical excellence, said Daniel L. Winterscheidt, Ph.D., NMC Program Director. The NMC approach includes extensive use of Integrated Project Teams (IPT), members of which are selected based on their mix of technical skills and capabilities, regardless of company size. This approach has led to a successful track record of pushing advanced technology forward toward implementation on weapons systems. A few recent examples are included in this article. The Navy ManTech program has increasingly placed emphasis on the reduction of total ownership cost (TOC), which the Navy defines as the full lifecycle cost of a weapon system includ- ADVANCED MATERIALS & PROCESSES SEPTEMBER

2 The pre-production weld-shaver tool is shown automatically shaving weld reinforcement on exterior hull panels on a DDG 51 at Bath Iron Works. Courtesy of BIW. ing research, development, procurement, operation, and disposal. NMC is operating several projects that are successfully addressing TOC for the four ship platforms on which ManTech is currently focused Virginia Class Submarines (VCS), CVN 78, DDG 1000/51, and the Littoral Combat Ship (LCS). In one current project, NMC is evaluating and developing white light-scanning technology for inspecting submarine and aircraft carrier propulsion-shaft tapers. This effort will lead to $10.8 million cost savings at four naval shipyards over five years. The IPT is working with industry to identify the most promising white light-scanning system, developing a prototype for shipyard use, and optimizing the prototype in response to testing and evaluation. Another NMC IPT is simplifying the complex design of the VCS weapons cradles to reduce costs and eliminate unnecessary labor to support the manufacturing rate required by the VCS Program. NMC is working with partners to develop and optimize the submerged arc welding process for use with a new four-headed, mechanized welding system to improve quality, reduce distortion, and significantly decrease build time for thecradle weldment. Expected cost savings range Control console from $635,000 to $1.3 million per hull. These are just a few examples of active projects using This track weld shaver dramatically reduces manual grinding and the associated medical and production costs, and greatly increases the weld reinforcement-removal rate. Courtesy of PushCorp Inc. Control umbilical Flex track Drive carriage innovative technology to solve manufacturing issues that lead to reduced acquisition and maintenance costs. Other recent successful efforts are highlighted below. Mechanized weld-shaver tools lowers shipbuilding costs Butt welding exterior ship panels together produces a weld reinforcement that exceeds DDG 1000 fairness requirements. As a result, approximately 23,000 ft (7010 m) of weld reinforcement must be hand ground flush with the hull. The manual weld removal process is slow, which increases shipbuilding costs, and the repetitive nature of hand grinding causes frequent injuries and costly medical expenses. An NMC project developed a lightweight, portable tool that mechanically faces the weld reinforcement, substantially reducing the amount of hand grinding and associated injury claims, labor costs, and production costs. The tool is expected to remove 80% of the weld reinforcement height at 40 ft/h (12 m/h), versus the current manual rate of 3 ft/h (0.9 m/h), while operating in a flat, vertical, horizontal, and inverted orientation. Based on shipyard assessments, NMC and the IPT developed the tool requirements and evaluated several metal removal technologies, including grinding, milling, and shaving. The project team developed and validated a track weld shaver concept using commercially available hardware. PushCorp Inc., Garland, Tex., was selected as the commercialization partner to support development of the tool, which was tested at Bath Iron Works (BIW), Bath, Maine, and Ingalls Shipbuilding, Pascagoula, Miss. The preproduction tools were delivered to BIW and Ingalls in June 2009, and BIW used them in the construction of DDG 51 and DDG The shipyards plan to use the tools on other ships, including the America-class amphibious assault ship (LHA 6), landing platform/dock (LPD), and National Security Cutter (NSC). The use of the preproduction tools allowed the shipyards to take advantage of their benefits, identify potential tool enhancements for future production tool acquisitions, and identify other processes that can leverage this technology. For instance, while the weld shaver was designed for a 2.25 in. (63 mm) wide weld, the system was tested to remove a 3 in. (76 mm) wide weld (MIL-100S) on a thick tee section for DDG As a result of this project, the track weld shaver technology is commercially available by PushCorp Inc. The tools are expected to achieve a cost reduction of $2.77M for the DDG 1000 Program, based on three ships. A modified version of the tool is being developed for weld back gouging, which further increases the value of the technology to the shipyards. The tool will also be used for the removal Weld shaver of lifting lugs on DDG 51 and up to 14,000 ft (4267 m) of weld protrusions on the LHA flight deck. BIW and Ingalls identified additional savings of $2.4M based on the ability to back gouge for DDG 1000, LHA 6, LPD 17, and the NSC. IPT members include: Bath Iron Works, DDG ADVANCED MATERIALS & PROCESSES SEPTEMBER 2011

3 Program Office, General Dynamics Electric Boat, Naval Surface Warfare Center, Carderock Div., Navy Metalworking Center, Ingalls Shipbuilding, and PushCorp Inc. Innovative processing of HSLA-100 reduces carrier weight The Navy was seeking solutions to reduce the weight and lower the center of gravity for the CVN 78 Class carrier to improve performance at a reasonable cost. An NMC project was initiated to increase the performance and strength of high-strength low-alloy (HSLA-100) steel through innovative processing. This included the use of continuous-cast slabs, thermomechanical controlled rolling, double austenitizing, and water quenching after tempering. These improvements enabled Newport News Shipbuilding (NNS), Va., to use this new HSLA-115 (115 ksi, or 793 MPa, yield strength) steel at reduced thickness, and, thus, reduced weight, while meeting all performance requirements for a critical structure application. Additional objectives were to evaluate HSLA-115 for a largescale production plate application; to determine the performance and manufacturability of HSLA-115, and to achieve welding and shipyard practice optimization and vendor qualification. Incorporating HSLA-115 on CVN 78 provides improved survivability, strength, and weight reduction at an affordable price. Implementation of HSLA-115 on CVN 78 Class has netted 132 long tons of topside weight savings per hull and a significant improvement in center of gravity. Increasing the performance and strength of HSLA-100 steel allowed using the material at a reduced thickness for CVN 78, lowering the ship s weight and center of gravity. Courtesy of ArcelorMittal. In addition, NNS conducted a trade-off study that determined HSLA-115 to be cost-neutral compared to the HSLA-100 baseline. While the HSLA-115 steel cost is slightly higher than HSLA-100, weld volume will decrease 10% due to the reduced thickness. For other potential applications, the improved minimum yield strength level of HSLA-115 also offers an enhanced factor of safety in areas where the application thickness may not be reduced, but where design performance and strength are enhanced without a weight penalty. Additional applications may be considered in future weapon system designs. How to work with ManTech/NMC While ManTech Centers of Excellence (COEs) have considerable technical capabilities to help solve the Navy s issues, they recognize that the best solutions are generally developed using a team approach. Well-structured, strong Integrated Project Teams (IPTs) are a key feature of Navy Metalworking Center s (NMC) approach to project development. IPTs include Navy Program Offices, weapon system prime contractors, system integrators, and key suppliers. Subcontracted industry partners are included based on their expertise and experience. The main objective of the Navy ManTech Program is to implement viable advanced manufacturing technology solutions that meet Navy needs while maximizing the financial return on investment to the Navy. Where do project ideas come from? NMC project managers and engineers leverage established contacts and relationships with other government and commercial organizations to gather candidate project ideas as shown in the illustration. Candidate project ideas undergo a detailed review process, which starts by ensuring the proposed effort meets DoD directives and ManTech Program goals, is technically viable, and has a high likelihood of implementation. If the idea passes preliminary screening, a more rigorous evaluation process includes factors such technical merit, overall cost benefit, implementation probability, and other potential benefits. Input is solicited from government, weapons system prime contractors, and industry, including an NMC Industry Advisory Board, to ensure the most advanced metalworking and manufacturing technologies are considered. In other words, the Navy ManTech program and its COEs are designed to gather novel ideas from various sources on how to meet the critical need to reduce acquisition and maintenance costs of U.S. Navy weapons systems. In his remarks at Sea-Air-Space Navy Metalworking Center project managers and engineers work with other government and commercial organizations to generate candidate project ideas for the U.S. Navy ManTech Program. in April 2011, Secretary of the Navy Ray Mabus reiterated that to achieve the fleet we need, ships must be affordable, and they have to come within budget and schedule. He said, in part, We have to set strict affordability targets and we have to do innovative things where it s possible to get the best value for the money. ADVANCED MATERIALS & PROCESSES SEPTEMBER

4 The Future Aircraft Carrier Program Office has approved the use of HSLA-115 in the CVN 78 Class baseline design, and HSLA-115 has been incorporated into the ship specifications and the fabrication document. More than 2000 tons of HSLA-115 have been procured and delivered for CVN 78 since March Implementation of HSLA- 115 was achieved ahead of schedule due to the combined efforts of the IPT. These steps included obtaining NAVSEA approval of the Material Selection Information after extensive certification testing, first article testing, and vendor Innovative technology garners awards In the past several years, the Navy Metalworking Center (NMC) received two Defense Manufacturing Technology Achievement Awards, which are given by the Department of Defense Joint Defense Manufacturing Technology Panel (JDMTP). NMC earned the 2010 award for the development and commercialization of a weld-shaver system that has wide applicability for military ships, DoD weapon systems, and commercial structures. The 2008 award was given to NMC for development of the LASer-welded corrugated-core (LASCOR) metallic sandwichpanel technology, which is currently being implemented on the DDG 1000 class of guided-missile destroyer ships, and is saving the Navy considerable acquisition cost. qualification, survivability testing for both plates and weldments, and NNS s weld cross qualification. In addition, NNS demonstrated acceptable forming and welded tiedown behavior with HSLA-115. IPT members include: Future Aircraft Carrier Program Office, Naval Surface Warfare Center, Carderock Div., Naval Sea Systems Command, Newport News Shipbuilding, Navy Metalworking Center, Arcelor-Mittal Steel, DDL Omni Engineering, Puget Sound Naval Shipyard, and Navy Joining Center. Hybrid laser-welded metallic sandwich panel technology NMC developed another novel solution that reduces weight and lowers the center of gravity for surface ships at a lower cost than other options. LASer-welded corrugated- CORe (LASCOR) metallic sandwich panels are stiff, lightweight steel structures that offer corrosion resistance, reduced weight, and less distortion. NMC and an IPT optimized the LASCOR design for materials, manufacturability, joining, structural, and protection performance and cost for Navy applications. This project demonstrated the capability to manufacture large ( in., or about mm) LAS- COR panels using CRES 2003, a lean duplex stainless steel from ATI Allegheny Ludlum Corp, Brackenridge, Pa. Ma ADVANCED MATERIALS & PROCESSES SEPTEMBER 2011

5 LASCOR offers a modular weight-reduction opportunity for door, deck, bulkhead, and other applications. Courtesy of Applied Thermal Sciences. terial properties, large-scale structural, and corrosion testing show that these stainless steel LASCOR panels provide enhanced strength, protection, and corrosion resistance compared to annealed Type 316L stainless steel. The panels demonstrated significant structural plasticity, which resulted in failure modes that are not catastrophic in nature as compared to other materials. Potential LASCOR applications investigated for implementation included decks, bulkheads, covers, doors, ramps, and other structural applications. LAS- COR panels have been implemented at BIW for DDG 1000 s berms and personnel safety barrier panels. These components are manufactured using CRES 2003 hybrid-laser welding technology, and the metallic sandwich panel-design technologies that were demonstrated on the NMC ManTech project. This combination of technologies was selected as the low-cost, technically compliant solution to meet weight, structural, heat, and other requirements while offering corrosion resistance and less distortion. The panels incorporate a variety of features such as integrated tie-down features, interior windows, attachments, and other flexibility options required to support shipboard integration requirements. IPT members include: Future Aircraft Carrier Program Office, Naval Surface Warfare Center, Carderock Div., Newport News Shipbuilding, Navy Metalworking Center, and Applied Thermal Sciences. The projects discussed in this article are just a glimpse into the leading-edge work being done through Navy ManTech to ensure that we have and will continue to have the U.S. Navy fleet needed to protect our interests at home and abroad. For more information on NMC funding and contract options, contact Dr. Daniel L. Winterscheidt, NMC Program Director (814/ ; winter@ctc.com). Other points of contact include Rob Akans, NMC Technical Director (703/ ; akansr@ctc.com), Denise Piastrelli, NMC Business Manager (717/ ; piastred@ctc.com), and Dianne Frye DeLisa, NMC Communications Specialist (814/ ; delisad@ctc.com), Navy Metalworking Center, 100 CTC Dr., Johnstown, PA 15904, ADVANCED MATERIALS & PROCESSES SEPTEMBER