Approaches to reduce cost of aluminum ship structures - NSRP

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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
Page 1 and 2: Approaches to reduce costof aluminu
Page 3 and 4: MiningAlumina• Founded in 1888.
Page 5 and 6: Alcoa Science & Technology7 Researc
Page 7 and 8: Advantages of aluminum in marinestr
Page 9 and 10: Naval Structures Initiative (NSI)
Page 11: Structural Design Capabilities• A
Page 15 and 16: Design for Cost• Once structures
Page 17 and 18: 17Manufacturing Cost Assessment•
Page 19 and 20: 19An example19
Page 21 and 22: Total Ownership Cost• True ship c
Page 23: Summary• Alcoa recognizes the res

Approaches to reduce cost of aluminum ship structures - NSRP

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