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Composite Components for Reduced Maintenance and Total Ownership Cost

Composite Components for Reduced Maintenance and Total Ownership Cost. Dr. Maureen Foley Naval Surface Warfare Center Carderock Division NSRP SDMT Panel Meeting July 2019. Distribution A - Approved for Public Release. Examples of Corroded Components. MIL-PRF-24758A Connector.

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Composite Components for Reduced Maintenance and Total Ownership Cost

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  1. Composite Components for Reduced Maintenance and Total Ownership Cost Dr. Maureen Foley Naval Surface Warfare Center Carderock Division NSRP SDMT Panel Meeting July 2019 Distribution A - Approved for Public Release

  2. Examples of Corroded Components MIL-PRF-24758A Connector Deck Drain Electrical Enclosure Stowage Box Sound Powered Phone Jack Box LHD well deck grating Vent Screen

  3. Methodology for New Component Development • Identification of Target Components • Input from maintenance personnel, ships’ forces, port engineers, Corrosion Control Assistance Teams (CCATs) and program office used to identify specific components which require frequent maintenance. • Requirements Definition • Analysis to determine the current requirements of the component. • Interactions with cognizant Technical Warrant Holders (TWHs). • Prototype Fabrication, Evaluation and Demonstration • Prototype of composite components fabricated under the Painting Center of Excellence (PCoE) Program and evaluated per the requirements defined during the Requirements Definition Phase. • Prototype iterated as necessary and Ship Change Document (SCD) generated to allow for fleet demonstrations. • Trial Inspection and Institutionalization • Inspections performed of the fielded component dependent on ship availability. • Installations documented and ships’ forces queried for feedback on success of installation and any lessons learned documented. • SCD’s, Temporary Alteration Installation (TEMPALTS), NAVSEA Drawing packages, and National Stock Numbers (NSN) established as part of the Institutionalization process depending on the component. Transition path determined through interactions with program office and stakeholders.

  4. Composite Deck Grating • Installed Composite Deck Grating Material • New phenolic resin based composite material • NAVSEA 803-6983499B, Deck Grating, GRP Installation and Details. Logistics • NSN for M-clip • 5340-01-529-4180 • NSNs for grating panel • 2540-01-654-4472 (3ft x 20ft) • 2040-01-660-9865 (4ft x 12ft) • 2540-01-654-4473 (4ft x 6ft) Updates • Potential for use internal to ship if applications are identified and approved through NAVSEA • CVN Catwalk • LSD Wing Wall • Benefits • 45% weight by reduction on CVN class catwalk (14 ton reduction) • Will not corrode like the legacy steel grating

  5. Composite Vent Screens Material • Modified Acrylic (MODAR) based composite material • NAVSEA DWG 803-6983500 Vent Screen, GRP, Installation and Details Logistics • Screen • NSN 5670-01-529-4266 • M-Clip • NSN – 5340-01-502-8426 • MRC • Developing MRC for cleaning and replacement parts Updates • FY19 requested vendor to change haze gray coating to polysiloxane based coating which should make it easier to clean off running rust in the future. LSD • Will not corrode like the legacy steel vent screen • Widely installed across the fleet on CVNs, L-ships and DDG classes

  6. Composite Electrical Enclosures • NAVSEA DWG 803-6983506 Electrical Enclosure, Rev B. • SCD 6922 All Surface Ships • Developing MRCs to be able to note replacement parts that are available (flop lids & covers) • Replace when fail SCD, up to ships to install, not currently planned into maintenance. • LSD Well Deck Control Station Logistics • NSNs assigned for various enclosures and replacement parts – see next page • Installation video in process will be posted to Carderock YouTube Site.

  7. Composite Electrical Enclosures Logistics Information

  8. Replacement Caps for Legacy Electrical Boxes • NSWC Carderock is in the process of qualifying 3D printed replacement caps for the threaded electrical receptacle (SYM 1099.1), sound powered phone jack box (SYM 2841, 2842, & 2843) and the Integrated Voice Communications Jack Box. All caps require a gasket to be installed to maintain watertight integrity requirements. • Technical Data packages will be submitted to DLA to develop NSNs. • Caps were developed under Cross Platform Systems Development Funding (CPSD).

  9. MIL-PRF-24758A Conduit Lightweight Corrosion Resistant End Fitting • One of the three approved vendors for the MIL-PRF-24758A conduit systems has replaced the legacy stainless steel nut and sleeve on the end connectors with a composite material to come up with a lightweight, environmentally durable, lower cost, hybrid end connector. • An Allowance Parts List(APL) of the NSNs on the next page is being developed and will be associated with the Corrosion Control APLs of the various ship classes that have this conduit installed.

  10. MIL-PRF-24758A Conduit Lightweight Corrosion Resistant End FittingLogistics Information

  11. Composite Deck Drain Inserts Material • Ultem 2300 (30% chopped glass Polyetherimide (PEI)) • NAVSEA DWG 803-6983511 Deck Drain Insert, Composite, 1.5 & 2.0 inch Logistics • NSN for all configurations • NSN for shoulder bolts • Updated MRC’s (A1JU and C4QV) and developed U-MRC J2NP for initial installation. • Carderock YouTube Video for Installation Guidance and Deck Drain Size and Type Identification. (unfinished) 2 inch Type C

  12. Composite Deck Drain InsertsLogistics Information Deck Drains APLs (most common) 2-INCH TYPE A – 2-INCH SEAL – APL 67A090013 2-INCH TYPE B – APL 67A140007 2-INCH TYPE C – APL 67A150009 2-INCH TYPE D – 2-INCH SEAL – APL 67A090011 Deck Drains NSNs (5 shoulder bolts inc. ) 2-INCH TYPE A – 2-INCH SEAL – NSN 4510-01-578-1143 2-INCH TYPE B – NSN 4510-01-633-0924 2-INCH TYPE C – NSN 4510-01-649-3042 2-INCH TYPE D – 2-INCH SEAL – NSN 4510-01-578-1209 1.5-INCH TYPE A – 2-INCH SEAL – NSN 4510-01-578-1029 1.5-INCH TYPE A – 4-INCH SEAL – NSN 4510-01-578-1022 2-INCH TYPE A – 4-INCH SEAL –NSN 4510-01-578-0844 1.5-INCH TYPE B – NSN 4510-01-632-7573 1.5-INCH TYPE D – 2-INCH SEAL – NSN 4510-01-578-0834 1.5-INCH TYPE D – 4-INCH SEAL – NSN 4510-01-593-9171 2-INCH TYPE D – 4-INCH SEAL – NSN 4510-01-578-1109 Corrosion Control APLs DDG 51 CLASS – APL 990990673 CG 47 CLASS – APL 990990588 LPD 17 CLASS – APL 99A150207 LHA 1 CLASS – APL 99A150206 LHD 1 CLASS – APL 99A150205 LSD 41/49 CLASS – APL 990990701 PC 1 CLASS – APL 99A160059 LCS 1 CLASS – APL 99A160090 LCC 19 CLASS - APL 99A160023 Ships can use corrosion control APL to initially purchase the composite deck drain insert and then update the ship configuration (OPNAV FORM 4790/CK) with composite deck drain APLs to reflect which and how many deck drain inserts were installed.

  13. 3D Printed Coamings for Composite Deck Drain Inserts • In many cases, a vertical pipe emits fluid onto a deck drain installed in a deck as shown below. • As composite deck drain inserts transition to the fleet there is a need for similar technology. • 3D printed coamings have been developed under CPSD funding. Technical data packages will be submitted to DLA to develop NSNs that can be bonded to the composite deck drain inserts.

  14. Composite Trough Cover Plates03 Level and Bridge Wings 03 Level and Bridge Wing • Port Engineer identified problem components. • Prototype parts fabricated at NSWC Carderock. • Glass fiber reinforced vinyl ester composite material coated with Formula 150 and MIL-PRF-24635 Polysiloxane, Deck gray. • Matched Drilled shipboard to meet mounting hole locations. • NSNs Developed • NSNs added to Corrosion Control APL. • Naval Message in process to alert the fleet of availability. • Installation Video on Carderock YouTube site • U-MRC under development Demonstration on USS NITZE DDG Only

  15. Composite Trough Cover PlateLogistics Information

  16. Composite Cover Plates (In Development) Composite Prototype • Development of Internal Strainer Plates in Sump and Bilge Areas. CG DDG LHD LPD

  17. Ready Service Lockers • Ready Service Lockers are installed on every ship in the fleet to provide local supply of ordnance and munitions. The purpose of the sunshield is to keep the heat from solar loading away from the locker. • Lockers are currently in many different sizes and shapes. Even lockers that store the same material can have a difference configuration on different ship classes. • Example of the .50 caliber ammunition locker DDG LSD CG (same ship)

  18. Range of Sizes and Materials • Larger RSLs tend to have aluminum sunshields which are typically indicate by the smaller attachment fasteners. Aluminum Sunshields Steel Sunshields

  19. Ready Service Lockers Other Platforms • ARMY LCM Platform has gray sunshields on the lockers. • MSC and DHS USCG Vessels have similar installations of RSLs for .50 caliberammunition and other weapons systems with white sunshields.

  20. Composite Sunshields for Ready Service Lockers (RSLs) • Lockers are typically powder coated steel which require re-powder coating every 3 years. The purpose of the sunshield is to keep the heat from solar loading away from the locker. • Extensive fire, smoke and toxicity testing have confirmed that composite materials are a viable solution. • Initial prototypes, fabricated at NSWCCD have been installed on LSD 50 and PC8, & PC14. • ONR Mantech has a FY19 project to develop a more efficient way to fabricate sunshields from flat panels. • Technical Director of Command Navy Regional Maintenance Centers has agreed to transition technology through RMCs as they perform the RSL maintenance. • NAVSEA Drawing 710-8817012 Sunshield Composite 50 CAL Ammunition Ready Service Locker has been developed to capture requirements of composite sunshield material and configuration for locker governed by NAVSEA Drawing 804-5184210. Metallic Sunshields Composite Sunshields

  21. Ready Service Lockers Per Ship • Each ship class has different configurations of RSLs. • Estimates based on ship check results *LHD 5 OHO reports total of 40 RSLs on board; Analysis is based on 33 RSLs inspected by NSWC Carderock

  22. Required Maintenance Costs • A maintenance requirement to “Request Repair Activity to Remove, Clean, Refurbish, and Reinstall Lockers” to be scheduled before the start of a TYCOM availability. • RMCs report this is being done as often as every 2-5 years. • SERMC/SWRMC reports every 12-18 months in some cases. • Involves the following: • 1 day, remove RSLs from ship using crane. • 1 day disassemble • 4 hours in furnace to burn off coatings, cools overnight. • 2 hours to sand blast remaining coating off 5 sunshields. • 1-2 hours of weld repair per shield of any rusted areas. • 5 hours to make a new shield if too far gone to repair. • 4 hours to prepare and coat • 1 day to reassemble • 1 day to return to ship using crane.

  23. Annual Maintenance Cost Avoidance Estimates • Assume 700 RSLs are refurbished every year throughout all the RMCs. • SWRMC estimates 250 RSLs per year and SERMC close to 100. • Assume 15 RSLs per ship with 5 sunshields each. • Approximately 47 ships per year. • Assume 20% sunshields need to be repaired, 10% need to be replaced. • Composite material eliminates time to put in/out of furnace, repair/replace of sunshields and preparation and coating. • Save approximately 8000 hours of labor at RMCs

  24. Full Scale Fire Testing • Full Scale Fire Testing using a .50 caliber ammunition locker was performed to determine how the flammable composite material would perform as compared to the metallic sunshield. The pass/fail criteria was that the temperature in the locker should be equivalent to the temperature with the metallic shield. The ammo box in the locker with metallic sunshields (left) exhibited more thermal damage than the one with the composite sunshields (right). The temperature within the ammo box with the composite sunshield was 11°C less than inside the ammo box with the metallic sunshield. Composite Sunshields Metallic Sunshields

  25. Running Rust Due to Clips • Corrosion of spring clips on the top sunshield mounting bracket and rust bleed on the bottom side of the sunshield • All of the spring clips (CRES is called out in the drawing, but appear to be steel) were corroded • Alternate attachment option for preventing corrosion will be pursued and the ISEAs have indicated no objection to this idea

  26. 3D Printed Corrosion Resistant Clips • Large area of running rust on current RSLs is due to the metallic hardware for mounting the sunshields to the locker • Typically attached with sheet metal bent into U-shape and welded to a nut • Currently developing 3D printed clip nuts as an attachment method • Initial prototype to 3/8-16 UNC sized bolt/nut (most common hardware among RSLs)

  27. PC 8 USS Zephyr Demonstration Note that a composite version for the backside sunshield could not be produced due to a size limitation with the currently available batch of composite material.

  28. PC 14 USS Tornado Demonstration Note that a composite version for the backside sunshield could not be produced due to a size limitation with the currently available batch of composite material.

  29. LSD 50 USS Carter Hall Demonstration Port Starboard

  30. Composite Gauge Panels(In Development) • Tasking started in FY19 to develop composite instrument panels for gauge dial indicators. They are installed in single and several ganged together versions across a wide variety of ship classes. • NAVSEA TWH has been identified and initial requirements list is starting to be populated based on NSTM 504 Chapter and MIL-G-18997. • Initial prototype version has been developed.

  31. Composite Stowage Boxes and Drip Pans (In Development) Summary • Ultem 2300 (30% chopped glass PEI)- demonstrated • Ultem (7781 glass fabric reinforced)-stronger material • Composite version of sheet metal processing. • Locally heat area and then bend material to form box. • Use thermoplastic welder tool to join seams. • Larger stowage boxes will use bonded angles of same material to provide strengthening at corners. USS BULKELEY (over 2 years installation) USS NITZE (over 4 years installation) Looking for examples of high maintenance stowage boxes to support FY20 ONR project.

  32. Proposed FY20 New Starts • Flame Arrestor Vent Screens • Weather Deck Drain Piping • Composite Louvers Slat Type Louvers Flame Arrestor Screens Corroded Aluminum Piping

  33. False Deck Panels(High Maintenance Item) • Nomex Core False Deck panels used in electrical spaces on ships are not durable and very expensive to install. • NSWCCD has been working closely with the NAVSEA TWHto develop a new Military Performance Specification that will outline the performance requirements for a new composite system. • Looking at new attachment methods such as composite fasteners and hook and loop (Velcro) to replace current fasteners that break. • Asking various TWHs if the black tape is actually needed for a composite installation or it is a hold over from metallic plating so that could eliminate in future installations. • Working closely with the ONR Mantech effort that is working to develop new materials for surface combatants and the flexible infrastructure used in future CVN installations

  34. Summary • Composite based components have been developed to reduce the required maintenance due to corrosion. • A standard methodology has been established to take new ideas from the fleet through the development process. • Institutionalization for new components is developed through interactions with TWHs, In-Service Engineering Agents (ISEA), fleet and program office. • It is imperative that all logistics development, APLs, Coordinated Ship Allowance List (COSAL), NSN, Planned Maintenance System (PMS), occurs during development to ensure a smooth transition to the fleet.

  35. Acknowledgements • The majority of this work has been funded under by PM Mark Lattner in NAVSEA 05PF under the Painting Center of Excellence program in FY19 and previous years under SEA 21, PMS 443 funding (SMARTWORK- Capital Investment for Labor) • Office of Naval Research Manufacturing Technology funding for several projects were funded by PM Neil Graf under the Composite Manufacturing Technology Center. • Cross Platform Systems Development program out of NAVSEA 05T PM Danesha Gross funded the development of the 3D printed caps and coamings.

  36. Contact Information Dr. Maureen Foley maureen.foley@navy.mil Naval Surface Warfare Center, Carderock Division Materials and Manufacturing Technology Division Integrated Manufacturing and Project Management Branch, Code 6102 301-227-5040

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