LIFT Joining-R1-3 Robust Distortion Control and ICME ImplementationNSRP Welding Technology Panel MeetingBuffalo, NY18th – 19th September 2018

T.D. Huang, Steve Scholler and Randy JohnsonHII - Ingalls Shipbuilding

2Project Teams and Roles

• Ingalls Shipbuilding Project lead

• The Ohio State University ICME material modeling, residual stress

• University of Michigan Distortion measurement and modeling

• Mass. Institute of Technology Cost and process flow modeling

• Edison Welding Institute Residual stress and shop floor implementation

• ESI – North America ICME and distortion model software developer

• NSWC – Carderock Division ICME material modeling, structural testing

• American Bureau of Shipping Classification and design consulting

• Comau Innovative fixturing support

Linking leaders in fabrication, technology, and manufacturing innovation

3ALMMII LIFT – Robust Distortion Control Project

4Test Article for Thin Panel Distortion Control

5Cost Model Calibration Level

Compared to average cost of NSC 1-8, bars show highest and lowest cost reported for each W/S

6Summary – ICME Application to Test Build

SA-05, SA 07, SA-08 Mock-up Test BuildSA-05, SA-07, SA-08 NSC-8 Unit 4130 Baseline

Cost Savings• Mock-up unit showed a significant savings from Steel Cutting (w/s 200), Pre-Fab (w/s 210), Panel Line

Assembly (w/s 220 & 225), Shell Shop (w/s 230) to CSA Unit Assembly (w/s 235)• Validated ICME tools were used to optimize build processes and sequences to reduce hull fitting and

welding costs A regression analysis was created to model the highest distorted NSC units and adjust the potential

savings based on the mock-up production cost results Utilizing the savings adjustments from the regression analysis, the top 20 distortion prone NSC units

were analyzed for cost savings and show significant labor hour savings when utilizing ICME for process improvement

7Distortion Control Improvement – Test Build Data Analyses

Dimensional Variation Improvement• ICME models were used effectively to simulate welding and production processes to

enable accurate prediction of distortion of the mock-up unit and then optimize unit build processes and sequences to reduce dimensional variation by an average of 30% as shown below:

8LIFT Part 2 – ICME Advanced Alloys Tasks and Objective

• ICME extension to advanced alloys (HSLA-100, HY-80, and HY-100)• Manufacture Test Articles• Distortion Measurement• Residual Stress Measurement• In order to fully develop the full spectrum of current and future ship steel

alloys for ICME implementation, a new project (Part 2) to expand material database models for HSLA-100, HY80, and HY100 for future ICME integration

• DH-36, HSLA-65, and HSLA-80 were developed during part 1 project • With all six of these material databases developed, the U.S. Navy

technical community will be able to leverage pedigreed material database for the main ship structural steel alloys in ship construction, thereby increasing confidence and robustness of welding-induced distortion and residual stress simulation for optimal ship structural performance in fracture and fatigue analysis

9LIFT Part 2 – ICME Advanced Alloys Project Status

• Full work plan, task breakdown, and budget has been completed and approved by ALMMII/LIFT and submitted to Navy ONR for final review/approval

• Sub-contractor (American Stress Technologies) to measure residual stress in the test panels after fabrication is complete

• HY-100 sample materials and welded test articles shipped by Ingalls to Ohio State and NSWC-Carderock for material classification testing

• Expected project kick-off ~ mid- to late- August 2018• Full training on functionality, use, and editing of the cost model

developed by MIT held on 7/23-7/26/18 at MIT– Use of cost model imperative to the successful implementation of ICME, as it allows

Ingalls Engineering and Operations management to make design and production process changes that are optimized by both quality and overall cost impact

– Will allow Ingalls to develop user interfaces to streamline the usability of the cost model for various production groups at Ingalls