presentation overview • primary hull structure • minehunters
TRANSCRIPT
1Eric Greene
Presentation Overview
• Primary Hull Structure• Minehunters• Special Forces & Boats
• Superstructure
• Foils and Appendages• Surface Ships• Submarines
• Components
2Eric Greene
OSPREY Class MinehunterPrimary Structure
3Eric Greene
Special Forces 11- Meter RIBPrimary Structure
In-Service Photos of the U.S. Navy Special Warfare’s 11-Meter RIB Built by U.S. Marine
4Eric Greene
BoatsPrimary Structure
Members of Inshore
Boat Unit Seventeen
(IBU 17) Patrol the Waters of
Apra Harbor,
Guam
At sea Aboard USS Blue Ridge (LCC 19) Sailors
Practice Deployment of Ship’s Small Boats
5Eric Greene
Swimmer Delivery VehiclesPrimary Structure
Special Forces Divers Work with a Swimmer Delivery Vehicle
Schematic of Northrop Grumman’s 65-foot Advanced
SEAL Delivery System
6Eric Greene
Helicopter Hanger for DDG 51 Flt IIASuperstructure
Composite Helicopter Hanger for DDG 51 Flight IIA Destroyer Builtat Northrop Grumman Ship Systems’ Gulfport Facility
Scheduled to be Installed on DDG 100
7Eric Greene
Forward Director RoomBuilt by Northrop
Grumman’s El Segundo Facility as Technology
Demonstrator for DDG 51 under ManTech Funding
DDG 51 Forward Director Room Superstructure
8Eric Greene
Surface ShipsFoils & Appendages
Composite MCM Rudder Built by Structural Composites Shown During Shock Trials
A Composite Twisted Rudderunder Development
9Eric Greene
SubmarinesFoils & Appendages
Advanced Composite Sail Envisioned for Virginia Class Submarines (top left) and 1/4-Scale Prototype Built by SeemannComposites (bottom left)
Composite Submarine Bow Dome Produced by
Goodrich Composites
10Eric Greene
Boat Davits
Priority High
Opportunity Potential to reduce maintenance andincrease personnel safety
TechnicalIssues
Functional design, safety factors, interfacewith metal hardware
Previous Work Advanced Lightweight Engineering in theNetherlands has developed a compositedavit for Davit International in Germany
Return onInvestment
MediumConventional Boat Davits
on USNS Comfort
Components
11Eric Greene
Bulkheads, Nonstructural
Priority Medium
Opportunity Opportunity to reduce cost and weight whileimproving fire resistance
TechnicalIssues
Fire, cost, supportability
Previous Work Currently use Nomex/phenolic sandwich
Return onInvestment
Medium
Webcore Hybrid Fabric-Web/Strut-Web
Core with Pre-Attached Fabric Proposed for Navy
SBIR Door Project
Components
12Eric Greene
Bulwarks
Priority Low
Opportunity Potential to reduce weight and maintenance
TechnicalIssues
Not suitable for retrofit
Previous Work LPD 17 design calls for composite bulwarks
Return onInvestment
Low
Bulwark Structure onLPD-17 under Construction and USS
INGRAHAM (FFG 61)
Components
13Eric Greene
Cable Passage Tubes
Priority Medium
Opportunity Reduced maintenance and ease of handling
TechnicalIssues
Fire and watertight certification
Previous Work
Return onInvestment
Medium
Bulkhead Example of Nelson Firestop Multi-Plug Tested to
US Navy Standards(DoD-Std-2003)
Components
14Eric Greene
Cable Hangers
Priority Medium
Opportunity Potential to reduce weightand maintenance
TechnicalIssues
Fire
Previous Work
Return onInvestment
MediumSingle Cable Composite Pedestal Cable Hanger
[Dennis Conroy & Larry Murphy, NSWCCD Code 823]
Components
15Eric Greene
CHT Systems
Priority High
Opportunity Eliminate severe corrosion and makemaintenance easier
TechnicalIssues
Fire; integrate with existing system elements
Previous Work Navy has fielded prototype compositesystems. The U.S. Navy is now specifyingGRP (fiberglass) piping and ladders for useinside the CHT tank, as this material holdsup extremely well in the sewageenvironment.
Return onInvestment
Medium
U.S. Navy Type III Marine Sanitation Device [US Navy Shipboard Environmental Information
Clearinghouse]
Components
16Eric Greene
Condensate Drains
Priority Medium
Opportunity Reduce corrosion and related maintenance
TechnicalIssues
Fire
Previous Work
Return onInvestment
High
Intake Fan Room/Plenum Drain on USS INCHON (MCS12), Dec 2000.
[Capital Investment for Labor Machinery Space Ventilation Program,
Norm Clayton & John Miller,NSWCCD Codes 624 & 9213]
Components
17Eric Greene
Counter Measure Washdown Piping
Priority High
Opportunity Aluminum tubing subject to corrosion andfouling
TechnicalIssues
Demonstrate survivability of compositesystem
Previous Work Fleet currently planning on replacing withCuNi system
Return onInvestment
High
Images of Topside Counter
Measure Washdown
[Photograph by Robert Benson
(above) and Cathy A.
Brenneman(below)]
Components
18Eric Greene
Deck Grating
Priority High
Opportunity Eliminate corrosion and related maintenanceand safety issues
TechnicalIssues
Fire and strength
Previous Work ERM-7 has fielded composite grating on 4ships; numerous unauthorized replacementsin the fleet.
NAVSEA Drwg 803-6983499, GRP DeckGrating specifies MODAR resin – partsexpected to be in supply system late FY 03
Return onInvestment
High
Composite Deck Grating onFFG-58 USS Samuel B. Roberts
Components
19Eric Greene
Door Hinges
Priority High
Opportunity Eliminate severe corrosion; makemaintenance and operation easier
TechnicalIssues
Fire, operability and strength
Previous Work Ken Brayton, NAVSEA 05P7 has led SBIR &other efforts to develop composite closures& mechanisms
Return onInvestment
High
Watertight Door Showing Wear Due to Hinge
Misalignment (above) and Corrosion (below)
Components
20Eric Greene
Doors
Priority High
Opportunity Corrosion, weight, stealth & ease ofoperation
TechnicalIssues
Fire & strength
Previous Work Prototypes have been developed by Ingallsand Webcore
Return onInvestment
High E-Glass/Vinyl Ester-PaneledDoor Built by Ingalls used inManTech Topside Project
Components
21Eric Greene
Electrical Enclosures
Priority High
Opportunity Reduce corrosion and related maintenance
TechnicalIssues
Fire and impact resistance
Previous Work ERM-7 is in the process of certifying ULTEM2300 electrical enclosures
Return onInvestment
High
Typical Corrosion-Related Failure (above) and ULTEM 2300 Box
Molded by Glenair (below)
Components
22Eric Greene
Fairings
Priority High
Opportunity Metal rope guards difficult to replaceunderwater
TechnicalIssues
Fastener interface
Previous Work Composite propulsion shaft rope guardsinstalled on Aircraft Carriers showing:
• Less than ½ the cost and weight oforiginal Cu-Ni
• Bolt-on vs. weld-on• Easy waterborne removal/install gives full
access to stave bearings & zincs
Return onInvestment
High
Installed Composite Fairwaters (NAVSEA 05M3)
Components
23Eric Greene
Fans & Blowers
Priority High
Opportunity Reduced corrosion, easier to maintain &quieter
TechnicalIssues
Fire, operability and strength
Previous Work NAVSEA PMS 400D32 is pursuingcomposite fans via SBIR & ManTechprograms
Return onInvestment
High
Typical Axial Fan
Components
24Eric Greene
Foundations
Priority High
Opportunity Severe corrosion on saltwater pumpfoundations is major maintenance issue andcontributes to machinery vibration; potentialto make machinery "quieter"
TechnicalIssues
Fire and shock
Previous Work Brunswick Defense built a filament-woundfoundation that was tested at NSWCCD
Return onInvestment
Medium
Filament Wound Machinery Foundation by Brunswick Defense
Components
25Eric Greene
Funnels & Deck Drains
Priority Medium
Opportunity Potential to reduce weight and maintenance
TechnicalIssues
Interface to metal structure
Previous Work ERM-7 has awarded SPARTA a contract tobuild prototype Type D deck drains. Type Ais scheduled for development in FY 04.
Return onInvestment
High
Type “A” Deck Drain
Typical Navy Funnels[Dolsey Ltd., Norfolk, VA]
Components
26Eric Greene
Gear Cases
Priority Low
Opportunity Reduce weight and make machinery quieter
TechnicalIssues
Strength, creep and high temperatureperformance
Previous Work Some "high end" work done by DTRC,Annapolis
Return onInvestment
LowExample of Reduction Gear Arrangement
for DDG 51 Class Where Each of the Ship's Two Propellers is Driven GE
Multiple-Input Reduction Gear Powered by Two GE Gas Turbines
Components
27Eric Greene
Handrails
Priority Medium
Opportunity Reduce maintenance and electronicinterference
TechnicalIssues
Cost and UV resistance
Previous Work Some isolated topside use
Return onInvestment
MediumA Sailor uses a Pneumatic Sander to Prepare Metal
Handrail for Painting Preservation
Components
28Eric Greene
Hatches
Priority High
Opportunity Reduced weight improves ease of operation;reduce maintenance; and improve stealth
TechnicalIssues
Hardware operability and fire resistance
Previous Work Ingalls’ door with composite panel; WebcoreSBIR project: UCSD cargo door
Return onInvestment
High
Scuttle Hatch Locking Device (above) and Lifting Assist
Mechanism (below)[Ken Brayton, 05P7]
Components
29Eric Greene
Heat Exchangers
Priority Medium
Opportunity Reduce corrosion and fouling
TechnicalIssues
Increase thermoconductivity at reasonablecost
Previous Work NSWC, Annapolis developed carbon epoxylaminates with conductive additives thatperformed better than Cu-Ni
Return onInvestment
Medium
Example of Fouled Heat Exchanger Head Inlet (above) [ERM, Fred Tsao, 05L] and
Relative Effectiveness of Composites (below) [Joseph Korczynski, NSWCCD]
Components
30Eric Greene
Helicopter Hanger Doors
Priority High
Opportunity Reduced corrosion maintenance andmachinery maintenance from less weight
TechnicalIssues
Strength and fire resistance
Previous Work Seemann Composites and BIW havedeveloped a composite helicopter door forDDG 51 Flt IIA. A composite helicopterhanger is scheduled to be installed on DDG-100.
Return onInvestment
Medium
Composite Helicopter Hanger First Article Door (above) and Operational Test Jig
(below) [Seemann Composites]
Components
31Eric Greene
Helicopter Net Frames
Priority High
Opportunity Reduce corrosion and weight
TechnicalIssues
Certification
Previous Work Frames changed from flame sprayed steelto CRES on DDG 79 and later; safety netcomponent hardware modified to CRESmaterial
Return onInvestment
High
Helicopter Net Frameson the USS Thach (FFG-43)
Components
32Eric Greene
Insulation
Priority Medium
Opportunity Reduce weight and maintenance.
TechnicalIssues
Cost
Previous Work Polyimide foam certified as fire-safeinsulation. The replacement of fiberglasswith polyimide foam hullboards on USN CG47 Class cruisers produced a weightreduction of approximately 50 tons.
Return onInvestment
Medium
Inspec Foams’ Thermal Hullboard for MIL-I-742 Type Applications with Glass Cloth
Laminated to SOLIMIDE®
Thermal Insulation Foam Weighing 0.15 lbs/ft2 at 1"
Thickness [Inspec]
Components
33Eric Greene
Ladders
Priority High
Opportunity Corrosion elimination and enhanced safety
TechnicalIssues
Cost and functionality
Previous Work Some isolated topside use of composites
Return onInvestment
High
Composite Ladder LocatedTopside on FFG-58,
the USS Samuel B. Roberts
Components
34Eric Greene
Life Rails & Lines
Priority High
Opportunity Reduce maintenance and electronicinterference
TechnicalIssues
Cost and UV resistance
Previous Work Some isolated topside use
Return onInvestment
Medium
Life Rails & Lines Located Topside on FFG-58, the USS Samuel B. Roberts
and the USS Gary (FFG-51)
Components
35Eric Greene
Louvers
Priority High
Opportunity Reduce maintenance and improve stealth
TechnicalIssues
Cost, certification and durability
Previous Work Composite louvers developed for the DDG51 class destroyers
Return onInvestment
High
Radar Absorbing Composite LouverDeveloped for the
DDG 51 Class Destroyers
Components
36Eric Greene
Mast Stays & Lines
Priority Medium
Opportunity Reduce weight, electronic interference andmaintenance
TechnicalIssues
End fittings and overall cost
Previous Work Used on recreational sailboats
Return onInvestment
High
Mast Arrangement on USS Elrod (FFG 55)Showing Stays and Lines
Components
37Eric Greene
Masts
Priority Medium
Opportunity Improve equipment supportability
TechnicalIssues
Cost
Previous Work AEM/S on USS Radford and LPD-17
Return onInvestment
Low
Advanced Enclosed Mast Systemfor LPD 17 Class Ships
Components
38Eric Greene
Motor Housings
Priority Low
Opportunity Improve equipment supportability
TechnicalIssues
Shock qualification
Previous Work
Return onInvestment
Low
Examples of Typical Electric Motor Housings
Components
39Eric Greene
Pipe Hangers
Priority High
Opportunity Eliminate corrosion and reduce pipevibration
TechnicalIssues
Cost and fire
Previous Work All hangers in weather, passagewaysto weather, in the mast, uptakes and dirtyside of CPS fan rooms have been changedto CRES 316L material on DDG 77 and later
Return onInvestment
High
Navy Type 1 and Type 2 Hangers[Dolsey Ltd., Norfolk, VA]
Components
40Eric Greene
Piping
Priority High
Opportunity Eliminate corrosion related maintenance:reduce weight & vibration
TechnicalIssues
Cost and fire
Previous Work Numerous offshore installations and Navyprototypes waiting congressional plus-up
Return onInvestment
High
Ameron’s Bondstrand® 2000USN MIL-P-24608 Pipe Assembly Weighs 3.6 pounds
Compared to 6.8 pounds for CuNi
FIBERBOND® Pipe Shown to Withstand 2000ºF Fires [EDO Specialty Plastics]
Components
41Eric Greene
Plenums
Priority High
Opportunity Eliminate severe corrosion and associatedmaintenance
TechnicalIssues
Cost and fire
Previous Work Plastic turning vanes have been fielded on alimited basis
Return onInvestment
HighProposed FFG Composite Plenum for 1180 CFM Nat Supply Aux Mchry Rm # 3, Helo Hgr #2, 1-278-2-Q
Components
42Eric Greene
Propellers
Priority Low
Opportunity Potential to make propellers quieter
TechnicalIssues
Strength and cost
Previous Work Existing systems for large yachts and R&Dwork on underwater propulsors
Return onInvestment
Low
The Contur® Propeller with Exchangeable Composite Blades
Offered by AIR Fertigung-Technologie GmbH, Germany
Components
43Eric Greene
Propulsion Shafting
Priority Medium
Opportunity Reduce vibration, weight and corrosionmaintenance
TechnicalIssues
Interface to metal couplings and cost
Previous Work Commercially available for high speed craft,NSWC Annapolis prototype work on AOE &subs
Return onInvestment
Medium
33 inch Diameter Filament WoundSection of Propulsion Shafting
Developed by DTRC, Annapolis for Testing to Meet AOE-Class Performance Requirements
[George Wilhelmi]
Components
44Eric Greene
Pump Internals
Priority High
Opportunity Increase mean time between failure andreduce time to repair
TechnicalIssues
Standardization of U.S. Navy pumppopulation
Previous Work ERM-7 has fielded composite pumpinternals on 19 ships
Return onInvestment
High
Navy Shock-Qualified CompositePump Internals Built by Flowserve
Components
45Eric Greene
Pumps
Priority High
Opportunity Reduce corrosion, much quicker to repairand quieter
TechnicalIssues
Cost and standardization of U.S. Navy pumppopulation
Previous Work ERM-7 has funded production of 1 sizepump, ManTech effort pending
Return onInvestment
High
Navy Shock-Qualified CompositePump Built by Flowserve and Installed
as Part of the Navy’sSMARTSHIP Program
Components
46Eric Greene
Retractable Bitts & ChocksPriority Medium
Opportunity Corrosion related maintenance and safety –corroded bitts difficult to retract
TechnicalIssues
Certification
Previous Work The following modifications have been madeto retractable bitts on DDG 79:• Modified surface preparation requirements• Improved Bar Rust coating system• Revised PMS MRC to require more
frequent maintenance• Drain lines installed in bitt chambers Bar
Rust coating on DDG 79 Bitts
Return onInvestment
Medium
Typical Retractable Bitt Showing Corrosion from Mooring Line Wear
and Standing Water
Components
47Eric Greene
Saltwater Piping
Priority High
Opportunity Potential to reduce corrosion, fouling andvibration problems
TechnicalIssues
Fire & certification
Previous Work Many offshore installations and proposedU.S. Navy use pending congressional plus-up
Return onInvestment
High Composite Pipe Installed in Severe Saltwater Ship Environment (Ameron®)
Components
48Eric Greene
Seachest Strainers
Priority High
Opportunity Reduce corrosion and integrate antifoulingagent
TechnicalIssues
Integrate effective, environmentally-friendlyantifouling
Previous Work PMS 400F funding pilot program
Return onInvestment
High
Fouled SeachestStrainer (top) Cutout
(middle) and Prototype
Composite Strainer (bottom)
Components
49Eric Greene
Shafting OverwrapsPriority High
Opportunity Current manual method labor intensive andnot durable. All shafting exposed toseawater must be coated to preventcorrosion, which can lead to fatigue failure.Glass Reinforced Plastic (GRP) (inaccordance with MIL-STD-2199) consists offour alternately wrapped layers of fiberglasscloth and Phillyclad 1775/620 resin.
TechnicalIssues
Environmentally-compliant process; bond tosteel; durability
Previous Work NNS currently funded as ManTech project
Return onInvestment
High
Main Propulsion Shafting General Arrangement [SupSalv]
Components
50Eric Greene
Stacks
Priority Low
Opportunity Potential to reduce topside weight andintegrate sensors
TechnicalIssues
Cost precludes retrofit
Previous Work Ingalls completed Low Observable Stackproject
Return onInvestment
Low Low Observable Multifunction Stack Concept [ONR]
Components
51Eric Greene
Stair Treads
Priority Medium
Opportunity Corrosion elimination and enhanced safety
TechnicalIssues
Fire
Previous Work Some unauthorized installations
Return onInvestment
Medium
Topside Example of Stair Treads onthe USS Samuel B. Roberts Showing
Wear of Painted Finish
Components
52Eric Greene
Stanchions
Priority Medium
Opportunity Reduce corrosion and weight
TechnicalIssues
Cost & functionality
Previous Work Some topside applications utilized productswith insufficient strength and UV protection.
Improved polyurethane/E-glass compositestanchions are currently installed on acarrier for evaluation. These stanchions canbend 90° and spring back to original shape.
Return onInvestment
MediumTopside Example of Stanchion on
the USS Samuel B. Roberts ShowingSurrounding Deck Grating
Components
53Eric Greene
Stowage Lockers
Priority High
Opportunity Reduce corrosion, weight & condensation
TechnicalIssues
Fire
Previous Work Some commercially available products
Return onInvestment
Medium
Damage Controlman Checks Fit of a Self Contained Breathing
Apparatus (SCBA) from a Damage Repair Locker
Components
54Eric Greene
Tanks
Priority High
Opportunity Reduce corrosion especially with saltwater &sewage systems - Tank and Voidpreservation has been reported by the TypeCommanders as their single largestmaintenance burden.
TechnicalIssues
Fire and certification
Previous Work Some prototype sewage treatment systemson carriers
Return onInvestment
High
Current Tank Coatings after 36 Months [ERM, Beau Brinckerhoff, 05M]
Components
55Eric Greene
Tank Vents
Priority High
Opportunity Reduce corrosion maintenance and weight
TechnicalIssues
Fire and certification
Previous Work
Return onInvestment
High
Topside Example of
Corroded Tank Vent on
the USS Samuel B.
Roberts
Tank Vent System
on the USNS
Comfort
Components
56Eric Greene
Topside Personnel Protection
Priority High
Opportunity FFG role for homeland security mayincrease vulnerability of topside personnel
TechnicalIssues
Cost, stowability & performance
Previous Work Kevlar®-reinforced systems have beenfielded on a limited basis, including USSRadford (DD-968) under MAC ALT 384 forup to forty ships supporting Desert Storm
Return onInvestment
High
Machine Gun Installation on the USS Elrod(FFG 55) and Armor Frames [MAC ALT 384]
Components
57Eric Greene
Topside Superstructure
Priority Medium
Opportunity Potential for in-situ repair of chronicaluminum deckhouse corrosion areas
TechnicalIssues
Fire and bond to aluminum
Previous Work Numerous prototype systems developedincluding MARITECH, Helo Hanger andManTech projects
Return onInvestment
Low
MARITECH Composite Superstructure Project Built by
Structural Composites and Ingallsusing Adhesive Technology
Components
58Eric Greene
Valves
Priority High
Opportunity Potential to extend service life, andsignificantly reduce maintenance andadverse mission impacts of corrosion-pronemetal components by using compositematerials. Potential to eliminate hydroblastcleaning of CHT system valves
TechnicalIssues
Shock qualification and fire
Previous Work Composite valves have passed shock test(NAVSEA drwg 803-6983491) and installedon 6 ships. The Capital Investment forLabor program plans on a major carrier CHTsystem installation.
Return onInvestment
High
Composite Ball-Valve Family Developed by
NSWCCD
Components
59Eric Greene
Vent Screens
Priority High
Opportunity Eliminate corrosion related maintenance andimprove operability
TechnicalIssues
Fire
Previous Work ERM-7 has fielded composite vent screenson 13 ships. NAVSEA drwg 803-6983500,Vent Screen, GRP Installation and Detailswill lead to MODAR screens in the supplysystem by the end of FY 03.
Return onInvestment
High
Example of Vent Screen Fielded by
ERM-7
Components
60Eric Greene
Ventilation Ducting
Priority High
Opportunity Eliminate corrosion related maintenance;improve ship air quality and improve shipavailability
TechnicalIssues
Cost
Previous Work NSWCCD and ManTech have fieldedprototype systems
Return onInvestment
High
Prototype Composite VentilationDuct System Built by Boeing and
Structural Composites Installed on the USS Samuel B. Roberts, FFG-58
Components
61Eric Greene
Weapon System Enclosures
Priority High
Opportunity Eliminate corrosion related maintenance andimprove operability
TechnicalIssues
Certification
Previous Work ASROC housings were unsuccessfully builtwith aluminum-honeycomb core composite
Return onInvestment
HighExample of Severely Corroded ASROC Housing That Utilized
Aluminum Honeycomb
Components