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Cleared for Public Release – Distribution Unlimited
Expanded Adhesive
Outfitting Applications
March 10, 2015
All Panel Meeting
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Presentation Outline
• Status of Previous NSRP Adhesive Outfitting Efforts
• Introduction to Expanded Adhesive Outfitting Applications
• Activities This Quarter
– Task 2 – Develop Requirements Matrix
– Task 3 – Develop Environmental and Survivability Test Plans
– Task 4 - Optimize the Adhesive Bonding Process
• Plans for Next Quarter
• Summary & Closing
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Ingalls Shipbuilding
• Building four classes of ships simultaneously—
nine ships now in production
• Won a contract in June 2013 to build 5 additional
Arleigh Burke-class destroyers
• Builder of record for LPD and LHA classes of
amphibious assault ships
• Builder of largest multi-mission National Security
Cutter for the U.S. Coast Guard
DDG 51 Surface Combatants LPD 17 Class Amphibious Transport
USCG National Security Cutter
LHA 6 Amphibious Assault Ship
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Previous NSRP Adhesive Outfitting Projects
4
NSRP Panel Projects:
Cost Reduction Measures for Local Cable Hanger Installations (SCRA 2012-439)
Cost Reduction Measures for Late Stage Outfitting (SCRA 2012-467)
Results:
The electrical and late stage items
survived shock tests
Ship Programs are pursuing approval to implement
Late Stage Items on Light Weight Shock Machine Late Stage Items on Vibration Table
Cable Hangers on Light Weight Shock Machine Cable Hangers on Vibration Table
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Expanded Adhesive Outfitting Applications
Objective:
To expand applications for adhesive outfitting beyond specifically tested
and approved items by developing allowable load limits and design rules
for adhesively bonded studs
Technical Approach:
– Determine failure loads through shock and vibration tests
– Qualify adhesives through environmental tests
– Follow NAVSEA adhesive guidelines
– Establish design rules and identify any changes to ship specifications
required for implementation
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Team Members
• Ingalls Shipbuilding – Project Lead
– Sean Murphy, Jarrod Gilmore, Mark Losset, John Walks, Ronnie Romero, D G
McMillion
• Bollinger Shipyards
– Dennis Fanguy, Barry Matherne
• National Technical Systems
– Mike Poslusny, Tucker Thompson, Conner Smith
• SCRA
– Mary Saady, Project Manager
• NASSCO
– Dan Sfiligoi, Project Technical Representative
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Team Member Roles
Ingalls Bollinger NTS
Project Initiation Lead Support Support
Develop Requirements Matrix Lead Support Support
Develop Environmental and Survivability Test Plans Lead Support Support
Optimize the Adhesive Bonding Process Lead Support Support
Finalize Guidelines for Selecting Adhesive Bonding Applications Lead Support Support
Develop Detailed Test Procedures for Phase II Tests Lead Support Support
Execution of NAVSEA Approved Testing and Development of Implementation Requirements
Lead Support Support
Prepare Test Articles and Conduct Environmental Tests Co-Lead Support Co-Lead
Conduct Survivability Tests Support Support Lead
Develop Recommended Changes for Mounting Applications and Specification Requirements
Lead Support Support
Update Implementation Plan for use of Adhesive Design Rules in Outfitting Applications
Lead Support Support
Project Management Lead Support Support
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Project Work Breakdown Structure (WBS)
Phase I: Development of Technical Requirements for Expanded
Adhesive Outfitting Applications
Task 1…..Project Initiation
Task 2…..Develop Requirements Matrix
Task 3…..Develop Environmental and Survivability Test Plans
Task 4…..Optimize the Adhesive Bonding Process
Task 5…..Finalize Guidelines for Selecting Adhesive Bonding Applications
Task 6…..Develop Detailed Test Procedures for Phase II Tests
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Project Work Breakdown Structure (WBS)
Phase II: Execution of NAVSEA Approved Testing and
Development of Implementation Requirements
Task 7.….Prepare Test Articles and Conduct Environmental Tests
Task 8…..Conduct Survivability Tests
Task 9…..Develop Recommended Changes for Mounting Applications and
Specification Requirements
Task 10….Update Implementation Plan for use of Adhesive Design Rules in
Outfitting Applications
Task 11….Project Management
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Milestone Schedule – Phase I
Milestone Title Due Date
1 Project Management Plan 9/18/2014
2 Quarterly Report 9/20/2014
3 Kickoff Meeting Minutes 9/30/2014
4 Requirements Matrix Report 11/25/2014
5 Quarterly Report 12/18/2014
6 Quarterly Technical Review Minutes 12/18/2014
7 Quarterly Report 3/20/2015
8 Quarterly Technical Review Minutes 3/30/2015
9 Draft Environmental and Survivability Test Plans 3/30/2015
10 Optimized Bonding Process Report 3/30/2015
11 Quarterly Report 6/20/2015
12 Quarterly Technical Review Minutes 6/30/2015
13 Final Environmental and Survivability Test Plans & Procedures 6/30/2015
14 Guidelines for Adhesive Bonding Applications 6/30/2015
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Milestone Schedule – Phase II
Milestone Title Due Date
15 Phase II Kickoff Meeting Minutes 7/30/2015
16 Quarterly Report 9/20/2015
17 Quarterly Technical Review Minutes 9/30/2015
18 Quarterly Report 12/18/2015
19 Quarterly Technical Review Minutes 12/18/2015
20 Survivability Test Report 1/30/2016
21 Quarterly Report 3/20/2016
22 Quarterly Technical Review Minutes 3/30/2016
23 Environmental Test Report 3/30/2016
24 Updated Implementation Plan 4/30/2016
25 Final Project Report 5/20/2016
26 Final Technical Review Minutes 5/30/2016
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Activities this Quarter
• Review the Requirements Matrix with Navy Technical Authorities
• Develop Draft Environmental and Survivability Test Plans
• Complete the Bonding Process Optimization Task
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Task 2: Develop Requirements Matrix
(November – December 2014)
The project team will review technical requirements for adhesive
outfitting qualification and prepare a requirements matrix.
–Task 2.1 Review current state of adhesive outfitting qualification
–Task 2.2 Develop Requirements Matrix** and test plan outline
–Task 2.3 Hold meeting with project team and Navy representatives
–Task 2.4 Solicit comments for incorporation in Task 3
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** Deliverable
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Requirements Matrix
General Specification Specification Name
078 Material Requirements
072 Survivability
073 Noise, Vibration and Resilient Mounts
075 Threaded Fasteners
304 Electric Cable
403 Personnel Safety
406 Equipment Grounding
640 General Requirements for Habitability Spaces
655 Laundry
665 Workshop, Laboratories, Test Areas, and
Portable Tool Issue Rooms
670 General Requirements for Stowage
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Task 3: Develop Environmental and Survivability
Test Plans (December 2014 – March 2015)
Develop and submit Environmental and Survivability Test
Plans to Navy representatives and Technical Warrant
Holders (TWHs) to obtain feedback for Phase II testing.
• Task 3.1 Draft test plans
• Task 3.2 Issue draft plans for comments
• Task 3.3 Incorporate comments
• Task 3.4 Issue plans for approval
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** Deliverable
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Environmental Test Plans
Sample Environmental
Test Plates
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Before After
Modified
Tensile
Modified
Offset Shear Photos Courtesy of Click Bond
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Environmental Test Plans
The plan procedures are limited to bond strength measurements of
adhesives under certain environmental conditions. These can be
summarized as follows:
• Bond Strength - Tensile and Shear
• Substrates - Steel, Aluminum, Corrosion Resistant Steel (CRES) Honeycomb
• Adhesives - Plexus AO420 and Click Bond CB200
• Attachments - Studs, Click Bond CB3200 or equal
• Conditions - Baseline, Corrosion / Aging, Elevated Temperature
• Variability - Lot to lot based on 3 lots
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Survivability
• Shock Test Plan and LWSM
Test by Ingalls
• Shock Test requirements
defined by Mil-S-901D
• Test Approach:
– Ranging Tests (single panel)
– Certification Tests (duplicate
panels)
– Repeat with multiple
substrates
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LWSM at Ingalls
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Survivability
• Vibration Test Plan by
Ingalls and NTS
• Vibration Tests at NTS
Ingalls
• Test requirements defined
by Mil-S-167-1
• Test Approach:
– Cut Test Articles from Shock
Test Plates
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Vibration Table at NTS
Photo Courtesy of NTS
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Task 4: Optimize the Adhesive Bonding Process
(December 2014 – March 2015)
This task will investigate potential improvements to the
shipyard adhesive bonding procedure and issue an
Optimized Bonding Process Report.
• Task 4.1 Review existing materials and procedures
• Task 4.2 Identify potential procedure improvements
• Task 4.3 Conduct screening tests
• Task 4.4 Conduct validation tests
• Task 4.5 Issue revised procedure
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** Deliverable
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Bonding Materials
Photo & Drawing Courtesy of Click Bond
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Identify Potential Process Improvements
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Flammable Solvent
Flammable Solvent Grind to Bare Metal
Flammable Solvents
Graphics Courtesy of Click Bond
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Alternate Cleaning Solvents
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F F F
Current
F = Flashpoint < 100F
*
* May not be representative due to excess solvent
Deliverable will include a comprehensive,
controlled installation procedure
Instructions Courtesy of Click Bond
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Plans for Next Quarter
• Finalize Guidelines for Adhesive Bonding
• Develop Detailed Test Procedures
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Questions
26
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