Navy Metalworking Center

Transcription

1 Navy Metalworking Center Overview and Representative Projects This presentation was prepared by the Navy Metalworking Center, operated by Concurrent Technologies Corporation, under Contract No. N D-0062 to the Office of Naval Research as part of the Navy ManTech Program. Approved for public release; distribution is unlimited.

2 Operated by Concurrent Technologies Corporation is an independent, nonprofit, applied scientific research and development professional services organization. 550 professionals; 20 locations More than 600,000 sq. ft., including 33,000 sq. ft. of lab space and 180,000 sq. ft. of high bay work/demonstration space Top 100 Government Contractor (Washington Technology) One of the World s Most Ethical Companies (Ethisphere Institute) Quality Standards: ISO 9001:2008 (Quality); ISO 14001:2004 (Environmental), AS9100 (Aerospace), CMMI Development Version 1.3 (Systems/Software Engineering); and OSHA VPP Star (Health and Safety)

3 NMC Overview Provide for the development of metalworking manufacturing technology to meet the needs of selected weapon systems or Program Offices under industrial production and sustainment Improve the affordability and mission capability of Navy systems by engaging in manufacturing initiatives that address the entire weapon system life cycle Primary Focus: Implementation of technology On the current contract, 45% of the projects have implemented results, and 31% of the projects are on track to implement results.

4 Focused Investment Strategy Concentrate resources on few high-priority naval platforms for maximum benefit Work with industrial facilities General Dynamics Bath Iron Works General Dynamics Electric Boat Ingalls Shipbuilding Lockheed Martin Newport News Shipbuilding Pratt & Whitney Raytheon Sikorsky Spirit AeroSystems

5 Technical Areas Metals and advanced metallic materials Metal-based composites Ceramics Metal / non-metal interface issues Shape-making processes Joining techniques Surface and heat treatment Primary metal materials manufacturing processes Materials characterization / testing Process design and control Product design and structural performance Environmental issues and recycling Information and data handling and transfer

6 Teaming Approach Extensive use of Integrated Project Teams (IPT) in all NMC ManTech projects Team members selected based entirely on having the right mix of technical skills and capabilities, regardless of company size

7 Project Development Process ManTech project concepts come from several sources: Ship and Aircraft Program Offices NAVSEA and NAVAIR Technical Codes NMC and Other ManTech COEs Shipyards, Prime Contractors and DoD Contractors Successful SBIR and STTR projects Industry Partners, including Small Businesses Projects are evaluated for: Alignment with NMC Scope Technical Maturity Platform Support Likelihood of Implementation Return of Investment Industry cost share/program office cost leverage is encouraged and is a factor in our project selection process

8 Advanced Metalworking Technologies Representative projects At the heart of the Navy Metalworking Center s work is improving metalworking technologies used in the construction of Navy weapons systems.

9 Mitigation of Cracking in Sensitized Aluminum An NMC project team developed and demonstrated a portable heat treatment system that reverses sensitization in 5456 series aluminum alloys, thereby restoring the affected material in the CG 47 ship s superstructure to a stabilized condition. NMC photo Up to $25.5M cost avoidance for 15 CG 47 ships serviced over five years The LCS program will also benefit from this improved technology

10 Machining Alloy 625 Propulsor Components NMC addressed manufacturing challenges associated with machining VCS propulsors made of nickel-based Alloy 625. The project team investigated innovative machine tooling, alternative cooling technologies, and other improvements. BAE implemented the project team s enhanced methods into production beginning in April NMC photo Ingalls Shipbuilding Photo Improved production rate and reduced anticipated cost increase $6M five-year savings

11 Precision Panel Inserts Improved trimming and welding methods will mitigate the significant distortion associated with the welding of inserts into thin panel plates at Ingalls for several ship classes (DDG 51, LPD/LX[R], LHA, and NSC). Improved weld sequencing procedures were integrated into Ingalls panel line in 2Q FY14. Lessons learned on this project can be used on future ship designs. Five-Year Benefit Across All Platforms 40,500+ labor-hour savings $2.6M estimated cost savings NMC image Ingalls Shipbuilding Photo

12 CVN Aircraft Elevator Cracking Remediation An NMC project team examined several methods for mitigating cracks in the support structures on CVN aircraft elevators. Analysis revealed that either ultrasonic impact treatment with thermal spray or weld buttering were effective on the aluminum alloy structures. In 1Q FY14, weld buttering was used to repair cracks on a CVN hull. NMC Photo Ingalls Shipbuilding Photo Effective methods to prevent or delay cracking will save significant repair costs throughout carriers service lives

13 Thin Plate Distortion Mitigation in DDG 51 New guidelines for producing, handling and thermal cutting of thin plates in shipbuilding are leading to reduced distortion and improved part accuracy. In the summer of 2013, Ingalls started evaluating alternative plate sourcing and upgrading the plasma cutting equipment to improve accuracy and to help reduce distortion in the production of DDG 114. $5.2M five-year savings Reduce cut part distortion by 58%-71% Improve cut part accuracy by 29% Ingalls Shipbuilding Photo Ingalls Shipbuilding Photo

14 Waterjet Inlet Tunnel (WjIT) Manufacturing An NMC project developed manufacturing solutions for the Lockheed Martin LCS Waterjet Inlet Tunnel entry edge. ABS approved casting methods that have reduced both the production cost and shipyard duration for construction. A three-piece, near-net casting was implemented in FY10. 75% reduction in labor hours 23% reduction in weld length 30% reduction in weight Improved geometric accuracy Ingalls Shipbuilding Photo Marinette Marine Corporation photos

15 Naval Applications of Laser Peening Technology An NMC project optimized the laser peening process for two Navy aircraft applications. The NMC project demonstrated and validated the potential of laser peening for improving the fatigue performance of these components. Improved fatigue and stress corrosion cracking resistance Increased service life Ingalls Shipbuilding Photo Metal Improvement Company photo

16 Alloy 625 Formability This project developed optimal forming practices for Alloy 625 in several critical CVN 78 components. In mid-2009, Newport News Shipbuilding implemented the practices developed in this project when forming these components. Minimize risk of cracking during forming of this costly material Reduce schedule delays Avoid costs to re-fabricate components Ingalls Shipbuilding Photo NMC photo

17 Cold Forming of Alloy 625 Fittings NMC and an IPT confirmed that a closed-die, cold forming technique can be economically and successfully applied to form large-bore, seamless Alloy 625 elbows for VCS and CVN piping systems. NNS procured elbows formed with this process for CVN 78 Class ships. Ingalls Shipbuilding Photo National Technical Systems photo >$500K cost savings for Alloy 625 fittings on CVN ranging in diameter from 2-8

18 Steel Casting Optimization This NMC project developed improved sand molding and molten metal pouring practices, which were implemented at the Newport News Shipbuilding foundry to significantly reduce casting defects Ingalls Shipbuilding Photo $712K per year cost avoidance Reduced production time Improved casting quality Newport News Shipbuilding (NNS) photo

19 Titanium Components for M777 Lightweight Howitzer NMC developed and implemented novel manufacturing approaches to reduce part count and innovative forming technologies to reduce manufacturing cost and material waste in the construction of the M777 Lightweight 155mm Howitzer. The part count for the spade was reduced from 60 to one through near-net-shape casting. NMC photo As of February 2013, NMC s project resulted in a nearly $68 million dollar savings for the 1,000 M777s that have been built

20 Joining Technologies Representative projects The Navy Metalworking Center is leading project teams to optimize several metal joining technologies for use in shipbuilding applications.

21 Weld Sequence Planning for Major Assemblies To address a major manufacturing challenge, an NMC project team is developing a user-friendly weld sequence planning tool to provide timely analytical data to guide weld sequencing of major ship assemblies. U.S. Navy photo $3.9M five-year cost savings for VCS $580K per CCS hull through reduced trial-and-error weld sequencing, mitigation of weld-induced distortion in the final product, and improved throughput

22 Shape Cutting and Welding Automation Automated processes will improve how fabricated stiffeners are fabricated for several Navy surface ships. An NMC project team characterized the causes of inaccuracies and inconsistent quality; developed process improvements; and designed, built, and tested tooling and prototype equipment to automate the stiffener manufacturing process. Ingalls photo $6.1M five-year labor savings at Ingalls across several platforms (LHA, LPD, DDG 51 and NSC class ships)

23 Modular Scalable Cold Plates for Naval Electronics A new design and manufacturing approach to edge-cooled naval electronic cold plate assemblies will improve performance and reduce manufacturability issues. An NMC project is developing friction stir welding processes to join modular heat exchangers to form a larger cold plate assembly based on a system designed and developed by Raytheon Integrated Defense Systems. Raytheon image 40% reduction in cold plate acquisition cost $2.7M cost savings for DDG 1002, CVN 79, and five DDG 51 Flight III hulls

24 Hull Fabrication Improvements An NMC project team helped to develop a robotic backgouging system for VCS hull butt joints. The project hardened the components against electromagnetic noise and physical hazards and integrated the components with a simple control system on a dedicated carriage. EB photo 25% reduction in welder hours when implementing this system to backgouge the hull weld joints in sequence with the robotic welding system

25 Exothermic Welding for CVN An NMC project developed an installation and repair procedure that uses an exothermic welding process to splice Navy shipboard power cables. NNS is currently using the procedure for installation of the Electromagnetic Aircraft Launch System. NMC photo Reduced risk to quality and schedule Increased system reliability and availability Initiation of a fleet-wide process for splicing power cables (especially applicable to future high-current applications, such as electric propulsion and pulse-energy systems)

26 Expanded Capabilities for Low-Cost Friction Stir Welding NMC developed an enhanced friction stir welding (FSW) system for use on Joint High Speed Vessel (JHSV) product forms such as thick plate and hollow core extrusions. The project team also devised processes and tooling for JHSV products. Reduced ship costs and weight Improved welded joint quality Nova Tech Engineering image

27 Alternative Brazing for Shipboard Use A semi-automated flame brazing system is addressing problems associated with manual flame brazing for CVN and VCS construction. In June 2012, NNS used the prototype brazing system in the construction of CVN 78. NNS has purchased three systems and intends to buy seven additional systems. NMC photo $2.6M cost savings in the construction and overhaul of CVN and the construction of VCS May benefit other platforms requiring flame brazing

28 Low-Cost Friction Stir Welding of Aluminum for LCS Applications An NMC project developed a transportable, low-cost FSW system that produces stiffened aluminum panels by edgewelding extruded aluminum shapes. Significant cost savings through reduced capital, labor and scrap cost NMC photos

29 Improved HSLA-80 T-Beams An alternative manufacturing process using HLAW was developed to produce thin-sectioned HSLA-80 T-beams for DDG 1000 with minimal distortion. The American Bureau of Shipping approved the procedure and Applied Thermal Sciences is qualified to manufacture HLAW T-beams in HSLA-80 and other steel alloys. 45% lower fabrication cost $600K overall cost savings per DDG 1000 hull ATS photo

30 Improved Arc Cladding Techniques An NMC project team developed a cladding procedure that optimizes hot wire Gas Tungsten Arc Welding (GTAW). General Dynamics Electric Boat purchased, installed and operates the new hot wire GTAW welding equipment, as recommended in the project. Arc Applications photo Increased deposition rate from 7.4 lbs per hour to 12.8 lbs per hour with equal or superior weld quality and low capital cost

31 Shipyard Processes Representative projects The Navy Metalworking Center teams with shipyards to develop improved shipyard processes.

32 Abrasive Blasting Arm for Man Lift NMC and Ingalls developed an easy-to-use mechanical arm to perform hull exterior abrasive blasting from a man lift during ship construction. Ingalls implemented the blasting arm in March Multiple sources can manufacture the system, and it can be transferred to other Navy construction programs, shipyards, and industries. Ingalls photo NMC photo $840K five-year savings for all platforms constructed at Ingalls (DDG 51, LHA, LPD, NSC) ~25% increased productivity (craftsmen can work longer) Ergonomic benefits anticipated as a result of reduced effort and exposure time

33 Self-Locating/Self-Fixtured Structure NMC and GDEB developed the manufacturing process for a new concept of fitting and joining the deck structures for CCS and the Virginia Payload Module (VPM). The self-locating, self-fixtured method will enable construction with notched beams that interlock and are continuous in both directions. Implementation is expected on CCS and VPM in FY19 at EB s Quonset Point facility. NMC photo Expected five-year $12.1M savings for CCS hulls and VPM sections

34 Pipe Cutting Machine Technology Improved equipment and tooling for onboard pipe cutting / beveling processes will enable reduced labor requirements and safer working conditions. Implementation is expected on VCS and CVN new construction and CVN Refueling and Complex Overhaul at NNS, and on DDG 51, LHA, LPD, and NSC new construction at Ingalls in 1Q FY18. U.S. Navy photo $3.5M projected five-year savings as a result of reduced labor for all hulls affected at NNS and Ingalls

35 Automated Hangar Manufacturing An NMC project team is streamlining the production of the several thousand hangers used to install and route pipe, ventilation, and cable on submarines. The team is developing an automated work cell to efficiently produce several hanger types and sizes. Flexible fit and weld fixtures developed on the project are being used in production. Complete implementation is expected at EB on VCS and CCS platforms beginning in FY18. U.S. Navy photo $10.3M potential five-year savings for the VCS and CCS programs through a reduction in rework / material handling and an increase in throughput

36 Automated Manufacturing Cell for Repetitive Assemblies A manufacturing work cell that automates and/or mechanizes various processes will reduce costs, improve ergonomics and quality, and increase throughput on multiple naval platforms. There are several process focus areas; mechanized stud welding has already been implemented. Ingalls photo $1.5M per year savings across all platforms constructed at Ingalls (DDG 51, LHA, LPD, and National Security Cutter [NSC])

37 Sonar Dome Fabrication Process Improvements NMC is investigating advanced material removal and metrology solutions to improve the fabrication of the DDG 51 class sonar dome. Customized automation tools and fixtures will reduce labor, and metrology technologies used throughout the construction process will improve dimensional accuracy, reducing the need for adjustments and repairs. The project solutions will be tested and transitioned through commercial partners starting with DDG 117 at Ingalls during 1Q FY16. $7.6M five-year savings Ingalls photo

38 CVN Vertical Build An NMC project will identify pre-outfitting that can be completed at a more optimal period of CVN 79 construction. This will improve on the CVN 78 build strategy, which saw much of the outfitting work completed in enclosed areas that were difficult to access and where labor frequently conflicted with other work. Project recommendations will be implemented at NNS in 1Q FY17. NNS photo A BCA will identify the benefits, including an expected significant cost reduction from efficiencies gained from optimized outfitting activities

39 Hull Production Automation Methods NMC developed technology solutions that will improve production fitting and welding on DDG 51 and LHA class ships, which are performed manually using labor-intensive processes. The project team identified and developed hull assembly fixturing, along with automated and/or mechanized processes for layout, cutting, and welding. Implementation began during the third quarter of FY15 on LHA 7 and DDG 117 at Ingalls Shipbuilding. $6.6M five-year cost savings across all platforms constructed at Ingalls 17,250 labor-hour savings Ingalls photo

40 Mechanized Cable Pulling NMC developed portable, power-assisted tools to help workers pull an entire cable evenly, pull portions of cable through immediate distances, and reduce the amount of effort required to pull cable through bends. Ingalls began implementation in 1Q FY16, NMC photo BIW started using the tools in 3Q FY16, and NNS plans to purchase the tools for evaluation in % labor savings to install Class III and Class IV cables on LHA, LPD, DDG, and NSC class ships $1.5M savings using the cable-pulling tools on a single hull of each of the programs under construction at Ingalls

41 Pipe Production Automation Methods NMC investigated and developed portable mechanized tools and automation techniques to improve pipe fitting, welding, and installation of several naval platforms manufactured at Ingalls. The IPT developed evaluated, and refined prototype designs and generated a manufacturing requirements package to facilitate commercialization of the technologies developed. Implementation began in $7M five-year cost savings for DDG 51, LHA, LPD, and NSC Ingalls photo

42 Transparent Armor Window Installation Improvements An NMC project team developed, built, and demonstrated a prototype fixture and associated processes that improved the transparent armor window installation on aircraft carriers. NNS HHS photo implemented the fixture and processes on CVN 78 in December 2014, which are expected to reduce window cracking/crazing. $322K cost avoidance in CVN 78 new construction and CVN 72 overhaul $715K cost avoidance on the remaining CVN 73-CVN 77 Nimitz class overhauls

43 Pipe Assembly Installation Improvements An NMC project team designed and progressively improved several tools that will increase the on-hull installation efficiencies of pipe assemblies for VCS. Shipyard use is expected at both EB and NNS in FY16. NNS also plans to use the tools in CVN overhaul activities. NMC photo 9,000 labor hour reduction $6M five-year savings

44 Improved Cable Routing Tools Innovative solutions are reducing labor costs and injury claims associated with the installation of electrical cables on VCS. The project team developed non-mechanized tools that improve cable routing EB photo practices, help workers manipulate and/or guide the cables, and reduce friction during routing operations. EB purchased 10 stuffing tube rollers for VCS production in FY14; implementation is expected at Ingalls and NNS. 10% 20% labor hour reduction $242K - $484K per hull cost avoidance Additional $39K - $51.5K per hull savings may be realized with purchasing changes for electrical lighting cable

45 Panel Line Process Improvements An NMC project team evaluated the equipment, processes and procedures related to the Ingalls Shipbuilding panel line and provided a plan to improve the line s overall performance. Ingalls began implementing the project s recommendations in 2013 for DDG 114 construction. Primary cost drivers targeted for improvement included fairing of excessive weld gaps, back side welding of plate joints and post-weld repair. Improved panel quality Reduced production schedule and cost >$2.1M five-year savings Ingalls photo

46 Plate Edge Preparation Improvements An NMC project identified and developed concepts for mechanized abrasive tools to remove light surface rust and primer from the edges and surfaces of large plates. BIW implemented the prototype edge system starting in 4Q FY12 on DDG D51 and DDG 1000 Class hulls; BIW implemented the surface tool in 2Q FY13 on the same classes. Significantly increased production rates $2M-$4M on future surface combatants NMC photo

47 Optimization of Blasting Operations To improve the process for preparing pipe surfaces before coating, an NMC project team optimized the blasting parameters for better grit blasting efficiency and developed more efficient ways to protect piping during blasting operations. EB implemented improved grit blasting parameters and a recommended stripping tape. PNS implemented other projectrecommended prep methods. NMC photo $367K savings per hull in reduced labor, materials, and disposal cost 25% reduced labor from improved grit blasting processes

48 Large Diameter Pipe Process Improvements An NMC project team developed pipe fixturing and welding process improvements for large diameter pipes in VCS. Prototype tools were initially transitioned to EB and NNS in April. Hands-free clamps were fully implemented at EB and NNS and a boss drill/weld station prototype was transitioned to NNS. Purge and blend tools are being further developed for shop and onhull applications in another ManTech project. 8,500 labor-hour reduction per hull $5.9M five-year savings EB photo

49 Efficient Environmental Controls for Painting Operations An NMC project recommended an environmental control system to minimize lost workdays associated with painting. Implementation was originally planned on SSN 785, but partial implementation was NMC image expedited for SSN 782 construction in the summer of >$200K per hull cost savings Minimized lost workdays associated with environmental conditions falling outside of the specification

50 Weld Seam Facing NMC developed a lightweight, portable tool that mechanically faces weld reinforcement on ship hull panels, substantially reducing the amount of hand grinding and associated injury BIW photos claims, labor costs, and production costs. BIW is using the tools in DDG 1000 class ship construction. The system has also been adapted to perform back gouging of weld joints and is being used at BIW in DDG 1000 construction. $2.8M cost reduction for 3 DDG 1000 hulls (weld shaving) $1.4M savings for 3 DDG 1000 hulls (back gouging)

51 HSLA-80 Plate Distortion Mitigation This project identified the root causes for distortion in HSLA-80 plates in DDG 1000 construction and determined revisions for future procurement specifications. The steel supplier implemented a project-identified advanced thermal monitoring system to improve plate heat treatment process control. And BIW implemented several project recommendations to reduce distortion. U.S. Navy photo courtesy of General Dynamics Cost avoidance due to labor to meet fit and fairness requirements

52 DDG 1000 Deckhouse Base Joint Improved welding and cutting processes were developed to weld the shoes of the DDG 1000 deckhouse to the deck without exceeding the temperature limitations of the deckhouse composite. The processes developed were implemented at Ingalls Shipbuilding in July Ingalls Shipbuilding photo Reduced labor by 4,700 hours per ship by allowing the welding to be done in long increments rather than the 18 permitted by the previous procedure. $840K total savings for the three ships in the class

53 Pipe Preparation and Welding Tools This project developed several customized pipe fitting tools that reduced the manual pipe preparation and welding labor of small diameter pipe details on VCS. Several inspection and welding tools identified by NMC are in use at the EB and NNS. NMC photo 2,400 labor-hours per hull ($168K) reduction with prototype pipe fixture and alignment clamping tools An additional 1,000 labor-hours per hull reduction from reduced fatigue

54 Web-based Welding Procedure System NMC developed a Web-based welding procedure system to reduce rejection rates of vendors submitted procedures. NNS and EB implemented the software tool in WeldQC, Inc., image Reduce the rejection rate of vendors procedures from 90% to 20% $1.6M annual savings from vendor and shipyard savings alone

55 Advanced Metallic Materials Representative projects The Navy Metalworking Center is improving Navy ships through the development and improved processing of advanced metallic materials.

56 Development of 15-5PH Forgings for Torpedo Muzzle Door Lever Arms This project developed a modified 15-5PH corrosionresistant steel to replace K- Monel in several critical NMC photo components in the torpedo tube muzzle door operating linkage of Navy submarines. The project also developed critical forging and heat treating parameters that will result in material properties tailored for this specific application. Implementation will start with the retrofit of existing components on LA class submarines beginning in FY15/16. $9.4M cost savings over the remaining life of 70 in-service hulls Material cost savings Mechanical improvements

57 HSLA-115 Evaluation and Implementation NMC led a project team in the development of HSLA-115, which provides increased yield strength with good toughness. Construction of CVN 78 with HSLA-115 material began in December More than 2,000 tons of HSLA- 115 have been procured and delivered for CVN 78. ArcelorMittal photo 132 long tons of topside weight savings on CVN 78

58 Design for Manufacturability Representative projects The Navy Metalworking Center uses a design for manufacturability approach when evaluating the manufacturability of components and assemblies.

59 Reverse-Brayton Cryocooler Manufacturing Improvements Improving the manufacturability and reducing the production cost of reverse-brayton cryocooler units will provide significant cost avoidance and make high-temperature superconducting degaussing systems more attractive for both near-term and future naval implementation. Creare image $7M five-year savings expected if implemented on future Navy surface combatants

60 Additive Manufacturing for Shipbuilding Applications An NMC project is demonstrating the cost and time benefits of AM to support the construction of Navy platforms. At Ingalls, the project team is assessing and demonstrating the use of AM during ship construction; at EB, the team is developing and demonstrating an AM process map that will allow the rapid production of tools and fixtures. Implementation is planned in FY17 at Ingalls and EB. Ingalls photo $800K per year acquisition cost savings at Ingalls for the construction of DDG, LHA, and LPD $200K acquisition cost savings per VCS at EB

61 Improved Weapons Magazine C-Channel This project is exploring manufacturing and installation process improvements, as well as alternative component materials and designs, for the Weapons Magazine Tie-down System (WMTDS) on Navy platforms. The IPT will develop and evaluate several concepts and construct prototypes to validate the process improvements. NNS photo $5.5M five-year cost savings on CVN 80; LHA 7 and LHA 8; and Ingalls-built DDG 51 class ships Improved first-time quality and final preservation Standardized installation approach for a cross-platform solution

62 Tow Cable Maintenance Winch This project is developing and testing a tow cable maintenance winch and ruggedized stowage container that will support the maintenance of the Remote Minehunting System (RMS) tow cable aboard LCS. NMC graphic Currently no winch meets Navy requirements for this application. The IPT will select and modify a COTS winch and ruggedized container and then evaluate them against functional, dimensional, and environmental requirements. $5.5M five-year acquisition cost savings

63 Flexible Infrastructure Track System NMC explored ways to improve the manufacturability of Flexible Infrastructure Track System at NNS. The project team developed, prototyped, and tested track components. After completion of installation time studies on the improved track and receipt of TWH and PO approvals, implementation is expected in the 2Q of FY16 on CVN 79. NNS photo $3.8M five-year savings for CVN 79, LHA 7/8, and CVN 73 overhaul

64 Degaussing System Manufacturing Improvements This project improved the manufacturability of the High Temperature Superconducting Degaussing system that will be implemented on a future surface combatant. The project team developed a customized soldering system and a high-yield bundling process for the uniquely shaped wire. The soldering system and bundling line have been transferred to the provider for production use. NMC photo $651K cost avoidance on a full HTSDG shipset order from the Navy Increased HTSDG system reliability, reduced lead time, and increased HTSDG cable capacity

65 Weapons Cradle Manufacturing Cost Reduction This project used Lean Manufacturing and Design for Manufacturability principles to improve the producibility of the VCS weapons cradles. NNS implemented the first Recommendations in 2010 on U.S. Navy photo SSN 781, incorporated additional enhancements on SSN in 2011, and expect to implement more on future hulls. $3.3M five-year savings for VCS program Additional cost savings when the remaining VCS and CCS hulls are included 42% documented reduction in fitting and welding labor hours per cradle

66 Weapons and Stores Elevator Doors Manufacturing Cost Reduction An NMC project team addressed weld distortion of the thin steel materials used on the CVN 78 weapons and stores elevator doors, using separate interim and permanent solutions. NNS began implementing the interim doors in 2013 and is expected to implement the permanent doors in 2018 on CVN 80. NMC photo Cost savings and cost avoidance on CVN 79 doors with interim corrective solution Expected labor and material cost savings with permanent solution doors on CVN 80 and follow-on hulls

67 Crane Roller Bracket Manufacturing Improvements NMC and partners investigated an alternative manufacturing approach for the roller brackets that connect the launch, recovery, and handling system crane to the LCS hull. The NMC image Rapid Response project developed a ready-to-machine cast bracket. Oldenburg Group Inc. will implement the design, most likely during 3Q FY15. $61K savings per LCS hull 2,000 pound weight savings

68 Low-Cost Pallet Systems This project developed, evaluated and transitioned manufacturing improvements for the DDG 1000 Advanced Gun Systems (AGS), including improved gas tungsten arc welding joint design and welding techniques, along with advanced machining and casting of critical projectile and propellant assembly system parts. NMC photo $6M per hull manufacturing cost reduction 190-pound per-pallet weight reduction which improves safety and survivability

69 LASCOR Panel Evaluation and Implementation This project optimized the design for manufacturability of LASCOR (LASer-welded corrugated-core) structures to enhance manufacturability, joining, structural and protection performance, weight and cost of this engineered structure. The technology has been implemented into the Deck Edge Safety Berms and Personnel Safety Barriers on DDG Reduced weight and cost Less distortion Corrosion resistance PSBs Berms

70 Coatings Application and Removal Representative projects The Navy Metalworking Center determines the optimum coatings application and removal process to use, as well as surface treatment, which can have a large impact on a weapons system s performance.

71 Improved Tiling Systems An NMC project team is improving the design, manufacture and application of Special Hull Treatment (SHT) on VCS by establishing requirements, identifying candidate processes and materials, and performing technical evaluations. The results are expected to be implemented on in-service ships in 2016 and new construction in U.S. Navy photo $600K per hull for new construction and $500K per year for fleet maintenance, primarily from improvements to the tile manufacturing process

72 GTC Durability Coating The project is improving the durability of Gradual Transition Coating (GTC) SONAR baffle tiles on VCS Seawolf class submarines. The project team is evaluating several materials and installation process parameters to select a durability coating that can be applied to the tile to improve service life. NMC photo Five-Year $3M potential net cost savings for in-service VCS $6M TOC savings for new construction VCS $4.4M cost avoidance for repairs on Seawolf class subs

73 Additive Isolation Coatings for Navy Fasteners An improved isolation process for fasteners on Navy piping system components will provide better protection against galvanic corrosion and reduce repair costs. This project validated the use of an improved isolation material that is integrated into the body of Navy-specified fastener alloys. Kestrel Partners Inc. photo $1.2M cost savings in total repair costs on the LPD 17 titanium seawater piping system over the next five years Savings are expected to grow to $4.1M over the following five years

74 NNSY Bilge and Tank Maintenance Platform An NMC-led IPT modified an existing remotely operated climber to perform a wide variety of inspection, decoating, and preservation tasks in hazardous or inaccessible shipyard areas. While Norfolk Naval Shipyard NMC photo is not implementing the climber, PSNSY & Intermediate Facility s moonshine lab uses the project-developed crawler as a prototype base to communicate the benefits of the technology. Potential to save $2.6M cost avoidance from reduced labor and preparation to allow human access

75 Advanced Bonding Methods for Steel Structures An NMC-led project team evaluated various improvements to the Surface Ship Hull Treatment (SSHT) on DDG 1000, including the use of alternative materials, efficient manufacturing and installation methods, and identifying means to improve the system s durability. NMC photo $3.5M per hull cost savings includes: $800K procurement cost reduction $1.6M overall reduction in installation cost $700K repair cost reduction $350K decommissioning cost reduction

76 Advanced Metrology and Inspection Technologies Representative projects The Navy Metalworking Center employs advanced metrology and inspection technologies to optimize manufacturing processes at shipyards and industrial facilities.

77 Efficient Identification of Plate Defects An NMC project team evaluated and down-selected 3-D inspection technologies capable of reliably and repeatedly identifying surface defects on ship surfaces before painting. The team is modifying a prototype automated visual inspection system and demonstrating its use in an industrial environment. NNS photo Five-Year $3.5M inspection cost savings over five years at NNS for CVN 78 class $650K cost savings over five years at Ingalls on DDG 51 and LHA

78 Integrated Metrology for Ship Construction An NMC project optimized advanced metrology solutions for individual components or subassemblies and incorporating the results into an integrated approach. A digital metrology solution, along with recommendations on how to apply its derived data to shipyard construction and quality processes, was implemented in the first half of FY16. Ingalls Shipbuilding photo $4.8M potential five-year savings for several platforms fabricated at Ingalls (DDG 51, LHA, LPD, NSC)

79 Non-destructive Inspection for Electron Beam Additive Manufacturing of Titanium An IPT investigated the effectiveness of traditional and advanced non-destructive inspection (NDI) techniques for parts fabricated through electron beam direct manufacturing (EBDM). Project results are planned for implementation by Lockheed Martin and Sciaky Inc. in NMC photo The development and implementation of approved NDI methods will enable the use of EBDM components on the F-35, which has the potential to reduce manufacturing cost by up to 47% and reduce lead time by up to 80%

80 Main Propulsion Shaft Taper Inspection An NMC project team evaluated and adapted white light scanning technology to inspect the tapered connections between the main propulsion shafts and inboard couplings on submarine and aircraft carriers. The team improved a commercially available system by developing features that automatically analyze the data, report results, and project the outline of out-of-specification areas onto the measured part. $6M cost savings by eliminating the purchase of taper inspection gauges $830K per year cost savings by eliminating the need to maintain existing taper gauges NMC photo

81 SHT Debond Detector & Debond Detector Improvements This NMC project developed a prototype impulse hammer tool that mimics the manual method of inspecting Special Hull Treatment (SHT) on VCS but measures the input force and response electronically. EB implemented the tool in February 2014 in the construction of SSN 787. A Rapid Response project is modifying the tool for in-service VCS. NMC photo $348K cost avoidance per hull by repairing SHT debonds during construction as opposed to after delivery

82 Improved Abrasive Technology An NMC project successfully segregated abrasive products for nuclear and non-nuclear work at EB to allow commercially available improved abrasive products to be used on >90% of the boat. The team established requirements, identified candidate abrasives, performed technical evaluations, and conducted production evaluations of the selected abrasives. NMC photo $7.5M five-year savings for VCS program Additional benefits may be realized for overhaul activities

83 Damping Material Application Improvement This project found alternative materials and installation methods for Type II, Class 1 and 2 damping tile on VCS. The IPT selected pressure-sensitive adhesives for use with current damping tile to significantly reduce installation labor. Performance has been evaluated on mid-size plates, but further evaluation on full-scale structures is required. $700K cost savings per hull NNS photo

84 For more information, contact: Dan Winterscheidt