AMIF2014 – [Nautica] Alfonso Barbato, Fincantieri’s experience in shipbuilding - Composite...

FINCANTIERI’S EXPERIENCE IN SHIPBUILDING COMPOSITE MATERIAL APPLICATION

ADVANCED MATERIALS INTERNATIONAL FORUMBari, 18-19 sept. 2014


FINCANTIERI71,1%

SEAF15%

MARIOTTI10%

ELSAG2,6%

INSEAN1,3%

CETENA S.p.A. - The Italian Ship Research Centre – is the Company of FINCANTIERI Group dedicated to research and consultancy in the naval and maritime field.

Since its foundation in 1962, CETENA has been involved in national and international research activities and has carried out research and consultancy in close collaboration with shipbuilders, shipowners, navies and universities.

GenovaGenovaTrieste

Castellammare

Palermo

Riva T.

Technological District on Engineering of Polymeric and Composite Materials and Structures

CETENA


Composite materials are widely used in the nautical field for:

Pleasure yachts…

Sailing boats…

Racing boats….

…but also in the shipbuiding world, composite materialsfind their applications, as in the following examples.

Pools made of composite materials:

• avoid corrosion problems of conventional pools in steel

• save weight (7 t per a big pool – 10x5x(h)2 m)

Swimming pool for cruise ship

in workshop… … on board!!!

Swimming pool for cruise ship


SONAR DOME

Sonar Dome (bulbous bow): allows the acoustic wave propagation for

SONAR minimises the wave resistance


Master model realizationMale master model realized by cnc milling

Steel structure + poliuretan panels GFRP coating Material to be milled

Dimensional quality control Dimensional quality control


Mould designFemale mould because:

Quality of external surface finish hydrodynamics requirements Possibility to reuse the mould

Mold subdivision in three components for an easy removal

of the part


Production supervision of the first prototypeCAD Production process

By NUOVACONNAVI


in workshop… … on board!!!


Ballistic protectionBallistic protection problems for naval ship can be solvedWith composite material panels, rather then ballistic steel;

Weight reductionBetter behaviourWeldabilidy problems between normal and ballistic steel


CFD Simulation: Geometrical optimisation Thermal and mechanic loads calculation

Simulazione FEM: Strustural verification for the foolowing loads:

Flame induced pressureGreen seaWind gustIceShock

Modal analisys

Real scale test: Real test of the material under flame load

Flame shield TESEO/MILAS per FREMM

Construction by NUOVA CONNAVI


Scope: – geometrical profile optimisation in order to drive gas exhaust

upward– Obtain the pressure field on the shield in the condition of

retained launch

Job phases:– Model calibration: getto del booster in campo libero– Due casi di studio:

• Retained launch from bottom canister• Retained launch from upper canister

Focus on:– Gas concentration in the lauchers areas– Thermal stress in the lauchers area– Pressure field acting on the shield (for FEM analisys)

Flame shield TESEO/MILAS : CFD Simulation (1/6)



Model calibration in free field


Basic configuration



Geometrical optimisation Introduction of a flap type element 150 mm extension of the fore part of the “spoon” 100 mm elevetion of the upper part of the “spoon” Deflector profile modification Aft support slope modification


Basic configuration – upper lauch


Final configuration: deck temperatures

Basic configuration – upper launch Final configuration – upper launch



Sostegni

Canister Canister

Altoparlante

Final configuration: transient temperature on selected locations



Scope: – Structural scantling of the shield– Structural scantling of the supports– Joints verification

Job phases:• Retained launch from bottom canister• Retained launch from upper canister• Vertical shock verifification

Focus on:– Stress levels– Maximum strains– Safety factors

Flame shield TESEO/MILAS : FEM Calculation (1/4)


Modelling

laminato base deflettore flap rinforzo a omega



Loads tranfer CFD FEM

CFD environmen

t


FEM environmen

t


Results

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20Shock 1.67 1.67 1.67 1.67 1.67 1.67 1.67 1.67 1.67 1.67 1.47 1.53 1.57 1.67 1.67 1.67 1.67 1.60 1.54 1.48

Lancio Alto 1.67 1.67 1.67 1.67 1.25 1.67 1.67 1.61 1.67 1.67 1.13 1.22 1.21 1.27 1.40 1.52 1.50 1.49 1.50 1.49Lancio Basso 1.64 1.65 1.65 1.66 1.67 1.67 1.67 1.67 1.67 1.67 1.66 1.67 1.67 1.67 1.67 1.67 1.67 1.67 1.67 1.66

SF - Viti Alettone/Cucchiaia

DISPLACEMENTS STRESS (Tsai-Wu) STRESS (Von Mises)


BOLTS verification


COMPOSITE MATERIAL SUPERSTRUCTURES FOR NAVAL SHIPS



Fincantieri and INTERMARINE cooperation for installation of composite Material superstructures on “Comandante Foscari” ship.

COMANDANTE FOSCARI - P493

Cantiere di costruzione

Cantieri di Riva Trigoso

Dislocamento 1.512 tonnellate

Lunghezza fuori tutto

88,6 metri

Larghezza 10,2 metri

Apparato motore

2 diesel Wärtsilä-NSD W18-V-26 XN

Potenza: 2 x 6480 KW (regime 1000 r.p.m.)

Velocità 25 nod



Main advantages• weight reduction abt. 35% with respect to steel solution• radar segnature control• easy maintenance and repair


COMPOSITE MATERIALS SHIP PROPELLERS

COMARPROP

Project BRITE/EURAM (1997 - 2000)

Partner:DERA (UK)CETENA (IT)Fincantieri (IT)MARINTEK (NO)CONSAR (IT)University of Athens (GR)Dowty Aerospace Propellers (UK)

Scope:

•Technological transfer from the aeronautical world to shipbuilding

•Design and test of two propeller types


Fincantieri and CETENA role

Hydrodynamic and structural design of a composite propeller for Alliance ship

in cooperation with Dowty Aerospace Propellers.

Test design and execution with dedicates tools for stress evaluation on the

propeller blades.



Design activities (ship Alliance) - 1

• Propelle rdesign (same blade shape of Alliance)

•Hydrodynamic loads calculation Calcolo dei carichi idrodinamici

• Material choice: carbon fibre, glass fibre, insulating facing

• Hub-blade connection design

• Iterative procedure for the disposal of orthotropic materials e structural

verification




• Cavitation tunnel test

• Real scale Fatigue test on blade

• Blades construction (5 + 1)




• SEA TRIALS EXECUTION



Results

Damaged blades during sea trials, due to structural problems

Need for:

- In depth analisys on hydrodinamic loads in off-design conditions

- New design of hub-blades connection

- New investigation on alternative composite materials



COMPOSITE MATERIALS SHIP MAST

From DESTRIERO…..


COMPOSITE MATERIALS SHIP MAST

…to the composite material integrated naval ship mast.

A reasearch project in cooperation with:

NUOVA CONNAVI Distretto Ligure Tecnologie MarineUNIGE

AMIF2014 – [Nautica] Alfonso Barbato, Fincantieri’s experience in shipbuilding - Composite...

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