Expanded Adhesive Outfitting Applications Ship Design and Material Technology Panel Meeting

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1 Expanded Adhesive Outfitting Applications Ship Design and Material Technology Panel Meeting June 16, 2015

2 Presentation Outline Status of Previous NSRP Adhesive Outfitting Efforts Update: Expanded Adhesive Outfitting Applications Deliverables From Last Quarter Draft Environmental and Survivability Test Plans Optimized Bonding Report & Procedure Activities for This Quarter Task 5: Finalize Guidelines for Selecting Adhesive Bonding Applications Task 6: Develop Detailed Test Procedures for Phase II Tests Plans for Next Quarter Summary & Closing 2

3 Ingalls Shipbuilding Building four classes of ships simultaneously nine ships now in production Won a contract in June 2013 to build 5 additional Arleigh Burke-class destroyers Builder of record for LPD and LHA classes of amphibious assault ships Builder of largest multi-mission National Security Cutter for the U.S. Coast Guard USCG National Security Cutter LPD 17 Class Amphibious Transport LHA 6 Amphibious Assault Ship DDG 51 Surface Combatants 3

4 Previous NSRP Adhesive Outfitting Projects NSRP Panel Projects: Cost Reduction Measures for Local Cable Hanger Installations (SCRA ) Cost Reduction Measures for Late Stage Outfitting (SCRA ) Status Update: Adhesive Outfitting Approved on LPD Class Ships The LPD Contract has been modified to reference adhesive bonding in the relevant Specification Sections. Applies to: Compartments that are signed off, completed, or adjoining spaces, or adjacent to completed tanks Items: Limits: Local cable runs and small boxes Deck berthing and furniture foundations Bulkhead foundations Repair, replacement, or relocation only Approved substrate only Approved Adhesive only Requires separate bonding / grounding Height restrictions Wire way hanger rules Requires NAVSEA approved bonding procedure This approval is a starting point which leaves plenty of room for expansion with experience and better data. 4

5 Expanded Adhesive Outfitting Applications Objective: To expand applications for adhesive outfitting beyond specifically tested and approved items by developing allowable load limits and design rules for adhesively bonded studs Technical Approach: Determine failure loads through shock and vibration tests Qualify adhesives through environmental tests Follow NAVSEA adhesive guidelines Establish design rules and identify any changes to ship specifications required for implementation 5

6 Team Members Ingalls Shipbuilding Project Lead Sean Murphy, Jarrod Gilmore, Mark Losset, John Walks, Ronnie Romero, D G McMillion Bollinger Shipyards Dennis Fanguy, Barry Matherne National Technical Systems Mike Poslusny, Tucker Thompson, Conner Smith SCRA Mary Saady, Project Manager NASSCO Dan Sfiligoi, Project Technical Representative 6

7 Team Member Roles Ingalls Bollinger NTS Project Initiation Lead Support Support Develop Requirements Matrix Lead Support Support Develop Environmental and Survivability Test Plans Lead Support Support Optimize the Adhesive Bonding Process Lead Support Support Finalize Guidelines for Selecting Adhesive Bonding Applications Lead Support Support Develop Detailed Test Procedures for Phase II Tests Lead Support Support Execution of NAVSEA Approved Testing and Development of Implementation Requirements Lead Support Support Prepare Test Articles and Conduct Environmental Tests Co-Lead Support Co-Lead Conduct Survivability Tests Support Support Lead Develop Recommended Changes for Mounting Applications and Specification Requirements Update Implementation Plan for use of Adhesive Design Rules in Outfitting Applications Lead Support Support Lead Support Support Project Management Lead Support Support 7

8 Project Work Breakdown Structure (WBS) Phase I: Development of Technical Requirements for Expanded Adhesive Outfitting Applications Task 1..Project Initiation Task 2..Develop Requirements Matrix Task 3..Develop Environmental and Survivability Test Plans Task 4..Optimize the Adhesive Bonding Process Task 5..Finalize Guidelines for Selecting Adhesive Bonding Applications Task 6..Develop Detailed Test Procedures for Phase II Tests 8

9 Project Work Breakdown Structure (WBS) Phase II: Execution of NAVSEA Approved Testing and Development of Implementation Requirements Task 7..Prepare Test Articles and Conduct Environmental Tests Task 8..Conduct Survivability Tests Task 9..Develop Recommended Changes for Mounting Applications and Specification Requirements Task 10.Update Implementation Plan for use of Adhesive Design Rules in Outfitting Applications Task 11.Project Management 9

10 Milestone Schedule Phase I Milestone Title Due Date 1 Project Management Plan 9/18/ Quarterly Report 9/20/ Kickoff Meeting Minutes 9/30/ Requirements Matrix Report 11/25/ Quarterly Report 12/18/ Quarterly Technical Review Minutes 12/18/ Quarterly Report 3/20/ Quarterly Technical Review Minutes 3/30/ Draft Environmental and Survivability Test Plans 3/30/ Optimized Bonding Process Report 3/30/ Quarterly Report 6/20/ Quarterly Technical Review Minutes 6/30/ Final Environmental and Survivability Test Plans & Procedures 6/30/ Guidelines for Adhesive Bonding Applications 6/30/

11 Milestone Schedule Phase II Milestone Title Due Date 15 Phase II Kickoff Meeting Minutes 7/30/ Quarterly Report 9/20/ Quarterly Technical Review Minutes 9/30/ Quarterly Report 12/18/ Quarterly Technical Review Minutes 12/18/ Survivability Test Report 1/30/ Quarterly Report 3/20/ Quarterly Technical Review Minutes 3/30/ Environmental Test Report 3/30/ Updated Implementation Plan 4/30/ Final Project Report 5/20/ Final Technical Review Minutes 5/30/

12 Activities this Quarter Task 5 - Finalize Guidelines for Selecting Adhesive Bonding Applications Task 6 - Develop Detailed Test Procedures for Phase II Tests Request Approval of Phase II Funding 12

13 Deliverables from Last Quarter Draft Environmental and Survivability Test Plans 13

14 Environmental Test Plan The test plan is designed to measure bond performance under a variety of conditions outlined by NAVSEA. The main parameters are: Test Plates - Steel, Aluminum, Corrosion Resistant Steel (CRES) Honeycomb Bond Strength - Tensile and Shear Adhesives - Plexus AO420 and Click Bond CB200 Attachments - Studs, Click Bond CB3200 Conditions - Baseline, Corrosion / Aging, Elevated Temperature Variability - Lot to lot based on 3 lots 14

15 Environmental Test Plans Test Plates 5 Replicates per Plate Steel, Aluminum, Corrosion Resistant Steel (CRES) Honeycomb 15

16 Environmental Test Plans Bond Performance Tensile and Shear Modified Tensile Modified Offset Shear 16

17 Environmental Test Plans Environmental conditions: Baseline: Room Temperature Dry (simulates interior, conditioned spaces) Corrosion / Aging: Extended exposure in salt fog and elevated temperature Fluid Immersion: Extended exposure at elevated temperature (water, cleaning fluid, lubricating oil) Elevated Temperatures: Adhesive upper limit and elevated temperature corresponding to an N-30 class boundary backside thermal rise) Curing Times: Curing curve at lower and upper application temperature limits Specific procedures / methods for fabricating test plates, bonding studs, and performing are included in the plan or appendices. 17

18 Survivability Test Plan Overall Shock Test Series Objective The main objective of all the shock testing is to determine the shock adequacy of various adhesive mounted stud configurations. This objective can be broken into 2 main categories: Test various configurations to failure to determine the typical failure modes of the adhesively mounted studs during shock. Test various configurations per the standards of MIL-S-901D for shock approval In general, the test series are developed to mitigate the risks of the numerous variables that are involved in stud mounted equipment. 18

19 Survivability Test Plan LWSM Test Description The LWSM test series will be performed for adhesive mounted stud configurations consisting of one and two studs up to the weight limits of the shock machine. Series A will test the test specimens to failure to determine the weight capacity and failure mode. Multiple specimens will be tested to ensure repeatability and reduce the affects of any anomalies in the testing or fabrication of the specimens. The stud will be adhesively mounted and tested with a baseline weight. After the initial three blows in one direction, the weight will be increased and the third blow will be repeated. The weight will continue to be increased until a failure occurs. This process will be done in both the top and back directions. These failures will help Shock Engineering determine the failure mode of each adhesively mounted stud. 19

Survivability Test Plan LWSM Test Description This figure is an example of the dummy weight fixture that will be used on the single stud test specimens.

20 Survivability Test Plan LWSM Test Description This figure is an example of the dummy weight fixture that will be used on the single stud test specimens. A similar approach will be used on the two stud configurations. Test specimen studs will be attached using standard manufacturing guidelines. The full details of the adhesive manufactured guidelines will be included in the detailed Series A and Series B Test Procedures. Single Adhesive Mounted Stud Test Dummy Weight 20

Approach: Ranging Tests (single panel) Certification Tests

21 Survivability Shock Test Plan and LWSM Test by Ingalls Shock Test requirements defined by Mil-S-901D Test Approach: Ranging Tests (single panel) Certification Tests (duplicate panels) Repeat with multiple substrates LWSM at Ingalls 21

22 Survivability Vibration Test Plan by Ingalls and NTS Vibration Tests at NTS Facility Test requirements defined by Mil-S Test Approach: Cut Test Articles from Shock Test Plates Photo Courtesy of NTS Vibration Table at NTS 22

23 Deliverables from Last Quarter Adhesive Bonding Optimization Report & Bonding Procedure 23

24 Example Click Bond Installation Procedure Instructions Courtesy of Click Bond

25 Adhesive Bonding Process Optimization Report This study and report was proposed for the following reasons: Certain bonding tests have produced variable results possibly due to differences in the procedures used. Better guidance is needed to select the proper surface preparation method for individual substrates. Better documentation is needed for bonding materials and process steps Lessons learned from previous installations shipyard experience needs to be captured and communicated. NAVSEA requested that a shipyard document the procedure in a controlled document. This report will build on previous work to document the knowledge and lessons learned from previous programs. The objective is to produce a comprehensive Adhesive Stud Bonding Procedure. 25

26 Adhesive Bond Process Optimization Report The discussion section will cover each step in the bonding process flow from beginning to end as shown below. Materials and operations will be discussed with respect to their suitability for shipboard installation and potential alternatives. Step 1. Assemble Materials Step 2. Verify Conditions Step 3. Solvent Wipe Stud Base Step 4. Solvent Clean and Abrade Substrate Step 5. Prepare Adhesive Step 6. Apply Adhesive and Install Stud Adhesive Bonding Process Flow 26

27 Highlights from Optimization Study Adhesives Potential issues with these adhesives are that they are flammable in the uncured state, they have a strong odor, they have very short working time in hot conditions, and they have limited shelf life unless stored under refrigeration. The project team discussed these topics and concluded they were not a major issue for current shipboard installations. While newer methacrylate adhesives have been developed to address these potential issues, the team determined that there was no reason to pursue them until a specification for qualifying the existing adhesives was developed. 27

Highlights from Optimization Study Abrasives Abrasives are used to prepare

The main objective in this report is to provide improved guidance on the

This incorporates lessons learned from experience with test programs and

The section on Cleaning and Abrading will provide additional guidance on

28 Highlights from Optimization Study Abrasives Abrasives are used to prepare the surface for adhesive bonding. The main objective in this report is to provide improved guidance on the types of abrasives and where they are used. This incorporates lessons learned from experience with test programs and training information provided by Click Bond. The section on Cleaning and Abrading will provide additional guidance on how the abraded surface should appear. Rigid A24R Wheel 36 Grit Fibre Disc Al. Oxide Hand Sanding Pad Diamond Hand Sanding Pad Abrasive Materials Used for Surface Preparation 28

29 Highlights from Optimization Study Non-Flammable Solvents Approved cleaning solvents are flammable and require special handling. Shock tests were conducted to compare the performance of two nonflammable cleaning solvents. The chart below shows that they did not consistently perform as well. They will not be carried forward into the full environmental and survivability test programs. Light Weight Shock Test Showing Score Based on Load at Failure 29

The approved procedure language for painted steel specifies: Abrade with 36 grit fiber disc PAINTED STEEL

30 Highlights from Optimization Study Secondary Surface Preparation Variation in bond strength is most commonly due to inadequate surface preparation. The approved procedure language for painted steel specifies: Abrade with 36 grit fiber disc PAINTED STEEL SUBSTRATE shall be prepared to Society for Protective Coatings (SSPC) surface preparation Standard SP-11. This is a visual standard requiring a minimum 1 mil. surface profile. Good - Rough Bad - Polished 30

31 Task 5 - Finalize Guidelines for Selecting Adhesive Bonding Applications The project seeks to document and consolidate the various guidelines that have been proposed for the use of adhesive bonding. NAVSEA has issued reference documents which provide a baseline set of guidelines. NAVSEA provided a template for adhesive use in conjunction with the project Requirement Matrix Discussions NAVSEA directed certain restrictions in the LPD contract modification. 31

32 Task 5 - Finalize Guidelines for Selecting Adhesive Bonding Applications NAVSEA Source documents (restricted distribution): Use of Adhesively Mounted Studs in Naval Applications (Carderock, 2011) Fire Performance Requirements for Adhesively Bonded Studs Used to Mount Furniture Items to Ship Boundaries (NSWCCD-61-TM ) The goal is to negotiate a set of guidelines with no distribution restrictions and get NAVSEA signoff 32

33 Task 6 - Develop Detailed Test Procedures for Phase II Tests Development of the detailed test procedures required to execute the Environmental and Survivability test plans are underway and expected to be complete by June 30, The Adhesive Bonding Procedure, which will be used to prepare test articles is complete and has been approved by NAVSEA. 33

34 Request Approval of Phase II Funding The remaining Phase I deliverables are: Adhesive Bonding Guidelines Detailed Test Plans and Procedures Upon submission of these reports (by June 30, 2015), the project team will request approve of Phase II funding. Phase II tasks include preparation of test articles, conducting tests, analyzing results, and preparing recommendations for implementation. 34

35 Plans for Next Quarter Kick-off Phase II Task 7 - Prepare Test Articles and Conduct Environmental Tests 35

36 36 Questions

NSRP. Strategic Investment Plan. National Shipbuilding Research Program MISSION

NSRP. Strategic Investment Plan. National Shipbuilding Research Program MISSION NSRP National Shipbuilding Research Program Strategic Investment Plan MISSION Manage and focus national shipbuilding and ship repair research and development funding on technologies that will reduce the