Navy Metalworking Center

Overview & Representative Projects

This presentation was prepared by the Navy Metalworking Center, operated by Concurrent Technologies Corporation, under Contract No. N00014-10-D-0062 to the Office of Naval Research as part of the Navy ManTech Program.

Approved for public release; distribution is unlimited.

Operated by

Concurrent Technologies CorporationCTC is an independent, nonprofit, applied scientific research and

development professional services organization.

• 1,100 professionals; 50+ 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)

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

Focused Investment StrategyConcentrate resources on few high-priority naval

platforms for maximum benefit

PEO (Subs) VIRGINIAORP

PEO (Ships)DDG 51 Class

PEO (Carriers)CVN 78 Class

PEO (JSF)F-35

Affordability Initiatives

PEO (LCS)LCS

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

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

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

Metalworking Technologies

At the heart of the Navy Metalworking Center’s work

is improving metalworking technologies used in the construction of Navy weapons systems.

Representative projects by capabilities

This project developed optimal forming practices for Alloy 625 in several critical CVN 78 components. Newport News Shipbuilding successfully implemented the practices developed in this project when forming these components.

Benefits• Minimize risk of cracking during

forming of this costly material• Reduce schedule delays• Avoid costs to re-fabricate

components

Indentifying Optimal Alloy 625 Formability

CTC photo

Cold Forming of Alloy 625 Fittings

NMC and the IPT confirmed that a closed-die, cold forming technique can be economically and successfully applied to large-bore, seamless Alloy 625 elbows on VCS and CVN piping systems. 

Benefits• Cost savings in excess of $500K for

Alloy 625 fittings on CVN ranging in diameter from 2- to 8-inches.

National Technical Systems photo

NMC explored alternative manufacturing processes to produce the WjIT entry edge for the Lockheed Martin LCS. A three-piece, near-net casting was developed and implemented using advanced casting technologies.

Waterjet Inlet Tunnel (WjIT) Manufacturing

Marinette Marine Corporation photos

Benefits• Reduced production cost• Reduced shipyard duration• 75% reduction in labor hours• 23% reduction in weld length• 30% reduction in weight• Improved geometric accuracy

This project addressed cryostat configuration and manufacturing issues associated with fabricating long lengths of flexible, vacuum-jacketed cryostats. Cryostat multilayer insulation systems devised on the project using a standardized cryogenic test facility have been validated on five-meter-long test samples.

Development of Long-Length, Flexible, Vacuum-Jacketed Cryostats

Potential Benefits• Cost savings and weight reduction

ONR Program Code 33 photo

Improved sand molding and molten metal pouring practices were developed and implemented at the NNS foundry to significantly reduce casting defects

Improved Steel Casting Practices

Benefits• $700K/yr cost savings• Reduced delivery time by up to 55 days for large steel castings

Newport News Shipbuilding (NNS) photo

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.

Benefits• Improved fatigue and stress

corrosion cracking resistance• Increased service life

Optimizing Laser Peening for Navy Aircraft

Metal Improvement Company photo

Technology Demonstrator titanium structural components for the N-UCAS were manufactured using Electron Beam Direct Manufacturing technologies. In addition, lightweight aluminum spars and ribs were produced using advanced high speed machining.

Electron Beam Direct Manufacturing

Benefits• Acquisition cost avoidance• 35% weight reduction of affected parts

Sciaky photo

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.

Titanium Components for M777 Lightweight Howitzer

Benefits• As of February 2013, NMC’s project resulted in a nearly $68 million

dollar savings for the 1,000 M777s that have been built.

CTC photo

Joining Technologies

The Navy Metalworking Center is leading project teams to optimize several metal

joining technologies for use in shipbuilding applications.

An NMC project developed a transportable, low-cost FSW system that produces stiffened aluminum panels by edge-welding extruded aluminum shapes.

Benefits• Significant cost savings

through reduced capital, labor and scrap cost

Low-Cost Friction Stir Welding (FSW) System

CTC photos

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 system could reduce ship costs, improve welded joint quality, and decrease vessel weight. The project team also devised processes and tooling for JHSV products.

Expanded Capability for Low-Cost FSW

Benefits• Capable of welding more product forms and sizes• Broader application throughout shipbuilding and other industries

Nova Tech Engineering image

Hybrid Laser Arc Welding of T-Beams

An alternative manufacturing process using HLAW was developed to produce thin-sectioned HSLA-80 T-beams for DDG 1000 with minimal distortion. 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. 

Benefits• 45% lower fabrication cost • $600K overall cost savings per DDG 1000 hull

ATS photo

A prototype flame brazing system is addressing problems associated with manual flame brazing for CVN and VCS construction. Since June 2012, NNS has been using the brazing system in the construction of CVN 78. NNS has purchased three systems and intends to buy seven additional systems.

Prototype Alternative Brazing System

Benefits• $2.6 million construction cost savings in the construction and

overhaul of CVN and the construction of VCS• May benefit other platforms requiring flame brazing

CTC photo

An NMC project developed installation and repair procedures for exothermic (thermite) welding for Navy shipboard power applications. Newport News Shipbuilding will implement the procedures to complete installation of the Electromagnetic Aircraft Launch System on CVN 78 in the fall of 2013.

Exothermic Welding for CVN

Benefits• Reduced risk to quality and schedule• Reduced labor-hours for installation and maintenance• Increased system reliability and availability• Initiation of a fleet-wide process for splicing large diameter power cables

Erico Products photo

An NMC project team developed a cladding procedure that optimizes hot wire Gas Tungsten Arc Welding (GTAW). The modified cladding process increases the deposition rate with equal or superior weld quality and low capital cost.

Improved Arc Cladding Procedure

Benefits• Capable of increasing deposition rate from 7.4 lbs/hour to 12.8 lbs/hour

Arc Applications photo

Shipyard Processes

The Navy Metalworking Center teams with shipyards to develop

improved shipyard processes.

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 claims, labor costs, and production costs.

ImplementationBIW is using the tools in DDG 51 and DDG 1000 construction. The system has also been adapted to perform back gouging of weld joints and is being used at BIW in DDG 1000 construction.

Mechanized Weld Removal System

Benefits• Weld shaving = $2.77M cost reduction for 3 DDG 1000 hulls

BIW photos

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 expedited for SSN 782 construction in the summer of 2010.

Environmental Control System in VCS Construction

Benefits• Nearly $300K cost savings per hull• Minimized lost workdays associated with environmental conditions falling

outside of the specification

CTC image

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 2010.

Improved Welding Procedures Prevents Overheating of Composite Joint

Benefits• Reduced labor by 4,700 hours per ship by allowing the welding to be

done in long increments rather than the 18 inches permitted by the previous procedure.

• $840K total savings for the three ships in the class

Ingalls Shipbuilding photo

NMC is leading a project to improve the process for blasting submarine hull structures during new construction. The project team will optimize the blasting parameters to improve grit blasting efficiency and will develop more efficient ways to protect piping during blasting operations. Initial implementation is expected in 2012 for SSN 787.

Optimization of Blasting Operations

Benefits• $350K savings per hull in reduced labor,

materials, and disposal cost

CTC photo

BIW is modifying and evaluating changes to its handling of HSLA-80 steel plates as a result of an NMC project that investigated distortion issues with the plates to be used in the construction of DDG 1000. This project identified the potential root causes for the distortion and determined revisions for future procurement specifications for HSLA-80 plate.

HSLA-80 Plate Distortion Mitigation

Benefits• Cost avoidance in

production

BIW image

This project developed 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 Electric Boat and Newport News Shipbuilding.

Pipe Preparation and Welding Tools

Benefits• Prototype pipe fixture and alignment clamping tools

demonstrated a reduction of 2,400 labor-hours/hull ($168K)• Reduced fatigue demonstrates an additional 1,000

labor-hours/hull reduction

CTC photo

NMC developed a Web-based welding procedure system to reduce rejection rates of vendors’ submitted procedures. Newport News Shipbuilding and Electric Boat implemented the software tool in 2010

Web-based Welding Procedure System

Benefits• Reduce the rejection rate of vendors’ procedures from 90% to 20%• $1.65M annual savings from vendor and shipyard savings alone

WeldQC, Inc., image

An NMC project identified and developed concepts for mechanized abrasive tools to remove light surface rust and primer from the edges of large plates. In 3Q FY 13, BIW implemented the developed prototype system; full implementation with commercially produced tools is expected in 4Q FY 13.

Plate Edge Preparation Improvements

BIW photo

Benefits• Potential 200% or greater increase in production rate • $4.5M savings per DDG 1000 hull• $2.5M savings per DDG 51 hull

Advanced Metallic Materials

The Navy Metalworking Center is improving Navy ships

through the development and improved processing

of advanced metallic materials.

NMC led a project team in the development of HSLA-115 steel, which provides increased yield strength with good toughness. Construction of CVN 78 began with HSLA-115 material in December 2009. More than 2,000 tons of HSLA-115 have been procured and delivered for CVN 78.

HSLA-115 Evaluation and Implementation

Benefits• Acquisition cost avoidance• 132 long tons of topside weight savings on CVN 78

ArcelorMittal photo

This project developed a modified 15-5PH corrosion-resistant steel to replace K-Monel® in several critical 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 VCS new construction and retrofit existing components on other classes in FY14.

Development of Corrosion-Resistant Components

Benefits• $9.4M cost savings over

the remaining life of 70 in-service hulls

• Material cost savings• Mechanical improvements CTC photo

Design for Manufacturability

The Navy Metalworking Center uses a

design for manufacturability approach when evaluating the manufacturability

of components and assemblies.

This project successfully reduced manufacturing cost and weight for the DDG 1000 Advanced Gun Systems (AGS) through various manufacturing improvements.

Improved Manufacturing of Advanced Gun Systems

Benefits• $5.3M per hull manufacturing cost

reduction• Reduced system weight that will

improve safety and survivability functions

CTC photo

This project is using Lean Manufacturing and Design for Manufacturability (DFM) principles to identify opportunities for improving the producibility of the submarines’ weapons cradles. The cradles have a long, thin shape and complex fabrication and application requirements, which create construction challenges.

Improving Producibility of Weapons Cradles

Benefits• 10% reduced rejection rate and rework• $612K to $1.2M cost savings per hull

U.S. Navy photo

This project optimized the LASCOR (LASer-

welded corrugated-CORe) design for materials, manufacturability, joining, structural and protection performance, weight and cost. The technology has been implemented into the Deck Edge Safety Berms and Personnel Safety Barriers on DDG 1000.

Berms PSBs

LASCOR Panel Evaluation and Implementation

Benefits• Reduced weight

and cost• Less distortion• Corrosion

resistance

Coatings Application and Removal

Determining the optimum coatings application and removal process, as well as what surface treatment to use,

can have a large impact on a weapons system’s performance.

This project evaluated various aspects of the DDG 1000 hull treatment system in an effort to reduce the cost for procurement, installation, repair, and decommissioning of hull treatment. Several recommendations are being incorporated in the development and modification of hull treatment specifications.

Alternative Materials / Application of Hull Treatment

Benefits• $3.5M per hull cost reduction

CTC photo

This project found alternative materials and installation methods for damping tile on VCS. The IPT down-selected pressure-sensitive adhesives and are currently evaluating performance to verify they meet the requirements for this application. It is expected that the results of this project will be implemented on SSN 786 in 2012.

Alternative Damping Materials

Benefits• Estimated $700K cost savings per hull.

NNS photo

Q & A

For more information, contact:Dan Winterscheidt

814-269-6840winter@ctc.com