Approaches to reduce cost of aluminum ship structures - NSRP

Approaches to reduce costof aluminum ship structuresBrett ConnerAlcoa Defense724-337-2896brett.conner@alcoa.com

Overview• What Alcoa and aluminum bring to the ship builder• Alcoa’s Collaborative Development Approach (ACDA)• Design for cost and cost modeling• Results2

MiningAlumina• Founded in 1888.• 34 Countries; 450 locations.• 97,000 Employees.• $31 Billion Revenue in 2007.• World-Class Aluminum Expertise.• Technology Leader.AerospaceAutomotiveSmeltingCommercialVehiclesIngotDefensePlateSheetExtrusionAl, SA, TiCastingsForgingsFastenersBuildings3

Technology LeadershipUnparalleledLightweight MetallicsTechnologyMetallics database unrivaled by any firm anywhere in theworld, the product of more than 100 years of research andengineering expertise– More than 60 years of experience in developing alloysand products for defense applicationsStructural DesignCompetenciesCritical design tools and competencies recognized inmultiple industries, including automotive, aerospace anddefense– Design capabilities not limited to a single material orproduct, but covering a range of solutions, includingthose that call for integration of aluminum with othermaterialsFabrication andAssembly CapabilitiesStrong manufacturing pedigree, chiefly born of its workmanufacturing integrated structures for the automotiveindustry– Extensive experience in producing prototypes rangingfrom full assemblies to individuals parts– Manufacturing and assembly issues viewed as criticalelements in the design process4

Alcoa Science & Technology7 Research & Development Locations:• Alcoa Technical Center, PA, USA• Alicante, Spain (fabrication)• Carson, CA, USA (fastening systems)• Crawfordsville, IN, USA (closures)• Kwinana, Australia (refining)• Richmond, VA, USA (packaging)• Whitehall, MI, USA (castings)3 External Technology Offices:• Beijing, China• Moscow, Russia• New Delhi, IndiaAlcoa Technical Center (ATC):• World’s largest light metals research facility• 600 scientists, engineers, technicians &support personnel• Full range of lab capabilities• Bench-scale to full production-scaleequipment & facilities• Research, Development and AppliedEngineering across all products, markets andprocesses5

ATC Core CapabilitiesProduct Design / DevelopmentBasic Science & Metallurgy• Alloy & temper development• Mechanical characterization• Deformation process design• Numerical simulations(material & process)• Metallurgical & engineeringstds.• Microstructurecharacterization• Constitutive equation dev.• Thermal process design• Subscale experimentalsimulation• Analytical Chemistry• Environmental Science• Surface ScienceManufacturing Systems /Technology• Control systems• Measurement systems• Manufacturing systemsanalysis• Statistical methodsMetal Processing• Melting/recycling• Metal treatment• Ingot casting• Continuous casting• Process analysis• Solidification• Particulate processing• Product design for:– Performance– Manufacturing– Cost• Computer-aided-engineering /design (CAE/CAD)• Design systems / methods /guidelines development• Material mechanics /characterization• Validation testingProduct Manufacturing• Metal shaping / forming• Machining / Metal removal• Joining & assembly• Rapid prototyping & tooling• Engineered Surfaces &Finishes6

Advantages of aluminum in marinestructures• Specific strength: high strength-to-weight ratio and density one-third that ofsteel• Excellent corrosion resistance in the marine environment:• Example: 5xxx series aluminum alloys do not need to be painted• Weldable• Formable• Recyclable• Ease of machining and ease of handling• Availability and diversity of semi-finished products to incorporate into shipstructures• Non-magnetic7

Alcoa’s Navy Initiative• Alcoa recognizes the resurgence in aluminum ships, and the Navy’s past andcurrent challenges with them.• Alcoa has a strategic initiative to help advance aluminum ship structurematerials, design and manufacturing.• Alcoa’s Navy initiative is aimed at improving cost, weight and performance ofprimary ship structure (hull, deckhouse and structural fittings).• Alcoa is offering its world-class experience and capabilities: Unmatched lightweight metallics knowledge Proven lightweight high-performance structural design capabilities Design tools, rules and standards Component, sub-assembly and systems manufacturing know-how• Alcoa’s multi-disciplinary approach and collaboration model have deliveredtremendous platform advancements in other industries (Commercial and DoD).• Program pull and support from the Navy and industry are needed to achievecomparable results.8

Naval Structures Initiative (NSI)• First formal engagement and contract activity (in recenthistory) between Alcoa and the Navy.• Support research and development of improved lightweightaluminum structures for LCS and other HSVs.• Alcoa and the Navy created IPTs with members from PEOShips, NAVSEA 05, NSWCCD, ABS, Primes, Shipyards, andNaval Architects: IPTs were setup in March 2008 sub-IPTs for each LCS JHSV being added in 20099

elasto - plasticboundar yMeeting the Ship ConstructionChallenge with Alcoa ExpertiseAlcoa can provide the innovations in ship design and construction required by the Navy andindustry to create more affordable vessels that will meet mission requirementsMaterial KnowledgeStructural DesignDesign Rules & ToolsManufacturingKnowledgeAlcoa is a leader inaluminum alloy researchand developmentAlcoa is a proven industrypartner for aluminumdesign solutions and candeliver trade studies foralternative designs to theNavy addressingWith decades of designand production experiencein aluminum, Alcoa has abreadth of knowledge thatcan be applied to theoptimization of navaldesign rules and toolsAlcoa’s advances in nextgenerationmanufacturingtechnology10

Structural Design Capabilities• Alcoa’s design technologies have been successfully leveragedacross multiple commercial and defense market segments– Rail cars– Transportation systems such as bulk trailers and intermodalcontainers– Cars and trucks– Commercial aerospace– Defense aerospace, land and marine systems• Design is driven by customer performance requirements andstandards– Alcoa has found that its design competencies and toolkits are fullytransferable to other market segments once we learn a customer’sperformance requirements and standards11

Alcoa Joining Process ResearchAlcoa is a leader in cutting-edge joining research, cover a broad gamut oftechnologies and applicationsAlcoa Joining Process Research AreasFriction Stir Welding (FSW)Gas Metal Arc Welding (GMAW)Magnetrically Impelled Arc ButtWelding (MIAB)• High frequency inductionresistance welding• Low and high temperaturebrazing• High temperature soldering• Magnetically impelled arc buttwelding (MIAB)• Gas metal arc welding(GMAW)• Flash welding• Resistance Spot welding withand without adhesives• Riveting (eg., Riv-bonding,blind rivets, self-piercingrivets, etc.)• Adhesive Bonding• Friction stir welding– Conventional– Fixed Bobbin tools• Friction welding• Laser beam welding with andwithout wire• Laser-Stir welding• Hybrid GMA/Laser welding• Hybrid Plasma/Laser welding• Cast joining• Double-wire gas metal arcwelding• Cold wire assisted plasmawelding• High frequency resistancewelding12

Alcoa Collaborative Development Approach (ACDA)- Collaborative IPT Teams (OEM, Alcoa, Military) -Phase IPhase IIPhase IIIPhase IVPhase V-Identify and Select Candidate Assemblies/Components-Develop and Evaluate Conceptual Designs-Finalize Conceptual Designs and Analyses-Develop and Evaluate Prototypes-Implement Designs in ProductionPartID1stgateConceptDesign2ndgateFinalDesign3rdgatePrototyping4thgateI II III IV VEx. Activities:Production• Opportunityidentification• Gather geometry,packaging, load req’s• Develop conceptredesign options• Prelim. evaluation ofconceptual redesigns• Down-selectconcepts for furtherdevelopment• Finalize partredesigns – detailedCAD and analysis• Evaluate advanceddesign concepts• Finalize total costsand plans forprototyping• Develop prototypepart fabrication andtest plans• Produce prototypeparts• Test prototypes andapprove forproduction1313

Collaboration: Who should beinvolvedShipyardPrimeNavalArchitectsProgramOfficeShipDesignManagersTechnicalWarrantHoldersABSNSWC

Design for Cost• Once structures are identified as opportunities for cost savings, Alcoa canbegin to develop concepts• Collaboration with the customer(s) identifies requirements and targets• The baseline structure or component must be defined and agreed upon• The baseline is then cost modeled• As concepts are developed they are cost modeled• The concepts are then evaluated for the above criteria• This process continues as concepts are downselected and refined15

16Cost Modeling Methodology• Manufacturing costs assessments developed with SEER-DFM(www.galorath.com), a commercially available software tool commonlyemployed in the Aerospace and Defense Industries– Parametric cost estimation based upon the application, platform, sizing,material, automation, etc. defined by the user.– Develops costs by comparing the user’s entries with similar items in ahistorical database.– Provides Recurring Manufacturing Costs for Individual Manufacturing Steps(labor, materials, and tooling)• Welding, Machining, NDT, Bolting, etc.– Does not provide NRC development costs and labor

17Manufacturing Cost Assessment• Commercial costingsoftware, SEER-MFG(www.galorath.com)employed by majorAerospace andDefense industries• Piece and processbasedcost structuredeveloped• Processes includemachining, surfacepreparation, fitup andwelding operations.17

18SEER-DFM Overview• Create or Refine Work BreakdownStructure Based Upon Design &Flowpath• Define Inputs to EachManufacturing Step

19An example19

Cost Estimates and ConceptEvaluation• Do any of the concepts meet your cost targets?• Are there other factors that need to be considered such as weight orrepairability?20

Total Ownership Cost• True ship costs extend beyond the cost to build the ship. These include:• Cost to maintain the ship structure including manpower costs• Cost in fuel to operate the ship• For commercial vessels, costs incurred by heavier than necessary structures• Hedlund-Åström 2009 in a life cycle cost analysis shows a 50% weightsavings design for a Ro-Ro superstructure by switching to aluminum• Weight reduction used as increased payload resulting in a break-evenpoint of around 5 years of operation• Costs to dispose of the vessel• Environmental factors• Ship designers and builders should use aluminum’s advantages to reducelife cycle cost• These life cycle factors can impact the shipbuilding costs as it candetermine which cost saving concepts are selected for application21

Results• Each opportunity identified that required a solution in cost has resulted in50-70% savings in recurring manufacturing cost• Each opportunity identified that required a solution in weight has receivedbetween 15-60% savings in weight• Immediate payoffs: solutions are being inserted onto LCS-3 and LCS-422

Summary• Alcoa recognizes the resurgence in aluminum ships, and the Navy’s pastand current challenges with them• Alcoa has a strategic initiative to help advance aluminum ship structurematerials, design and manufacturing• Alcoa is offering its world-class experience and capabilities: Unmatched lightweight metallics knowledge Proven lightweight high-performance structural design capabilities Design tools, rules and standards Component, sub-assembly and systems manufacturing know-how• Alcoa’s multi-disciplinary approach and collaboration model are deliveringresults saving costs and weight for shipbuilders23