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.
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Concurrent Technologies Corporation CTC is an independent, nonprofit, applied scientific research and
development professional services organization.
• 1,400+ 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/EH&S Management System comprised of industry-best
models: 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 Strategy Concentrate resources on few high-priority naval
platforms for maximum benefit
PEO (Subs)
VIRGINIA
ORP
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
• Single-piece investment cast spades saved more than $40M
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 will address problems
associated with manual flame
brazing for CVN and VCS
construction. After successful
qualification, the system was
implemented at Newport News
Shipbuilding in June 2012.
Prototype Alternative Brazing System
Benefits
• $2.6 million construction cost savings in the construction and
overhaul of CVN and 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.
A mechanized weld reinforcement
removal system is significantly
increasing removal rate. The tools have
been implemented at BIW in the
construction of DDG 51 and DDG 1000
and are awaiting implementation on an
LHA at Ingalls Shipbuilding. 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
• Back gouging = $2.63M cost reduction for DDG 1000, LHA-6, LPD-17,
and NSC
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
NMC is developing a prototype
system to minimize the amount of
manual grinding on large plates to
be welded in DDG 1000 class
construction.
Benefits
• 25% increased production rate
• $2.5M savings per hull
• Potential 50% reduction in
shipyard injury claims due to
grinding
Plate Edge Preparation Improvements
BIW photo
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
The project team will investigate,
modify, and demonstrate temporary
coatings / materials that prevent or
reduce damage and corrosion that
occurs during shipbuilding.
Implementation is expected on
some CVN 79 modules in FY12;
future DDG 51 Class vessels, DDG
113 and DDG 114; and LHA 6.
Temporary Coating Protects Ships
During Construction
Benefits
• For CVN 78 Class, Estimated $1.5M per hull savings
• For DDG 51 Class, Estimated $125K per hull savings
General Chemical Corp. 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
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