DEFENSE MAINT SMP 04 - SAE InternationalMr. William Craig Norfolk Naval Shipyard Captain Joseph Campbell NAVSEA 04 RADM Klemm NAVSEA VADM Balisle. 29 SEP 04 Overview 7 Naval Foundry

Overview

Keeping America’s Navy #1in the World

229 SEP 04 Overview

Naval Foundry and Propeller Center (NFPC)

Purpose

• To provide an overview of the Naval Foundry and Propeller Center, manufacturer of the world’s most advanced propellers and cast components

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Background • Mission

– NFPC exists to provide an organic source for the manufacture and repair of propellers for the United States Navy. While we maintain the capability to manufacture and repair propellers for all types of naval vessels, the core of our mission is the production of the world’s most advanced propellers and propulsors, those for our submarine fleet.

– To satisfy that mission and the demanding technical requirements associated with submarine propulsor manufacturing, NFPC maintains an inventory of unique manufacturing equipment, measurement systems and skilled craftsmen and engineers. In combination, these assets provide the Navy with a full spectrum capability that translates the hydrodynamicist’s concept and design into the best propellers and propulsors in the world.

– NFPC has been designated (CNO N43 Ltr. 3 FEB 97) the "National Consolidated Naval Ship Foundry" with the mission of providing castings previously manufactured at NSYs, IMFs and SIMAs. In addition to providing the Fleet with a source for emergent, hard to cast items, this second mission serves a critical function at NFPC by aiding in workload leveling and enhancing operational efficiency.

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Background

• Foundry and Propeller Shop in operation for over 85 Years• Foundry, Propeller Shop and support operations were part

of Philadelphia Naval Shipyard• BRAC ‘91 closed Philadelphia Naval Shipyard, retained

Foundry and Propeller Shop• 9/95 NFPC stood up as a Detachment of Norfolk Naval

Shipyard• Foundry, propeller manufacturing and support operations

consolidated from 16 buildings into 5• 2/97 All Naval Shipyard and IMA foundry work consolidated

at NFPC– Strategic Assets transferred to NFPC from closed facilities

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Background • NFPC is a core logistics facility & NAVSEA Core

Equity.– ASN/COMNAVSEA letters support NFPC as a core

facility– The Navy’s submarine industrial base for the

manufacture of propulsors and propellers– NFPC is the only propeller manufacturer for Trident,

Los Angeles & Virginia Class submarines– The Navy’s only organic source of cast components for

ships– Only co-located foundry and numerically controlled (NC)

propeller machining facility in the US

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Chain of Command

Naval Foundry & Propeller CenterMr. Walter Youngheim

Norfolk Naval Shipyard DetachmentPhiladelphia

Mr. William Craig

Norfolk Naval ShipyardCaptain Joseph Campbell

NAVSEA 04RADM Klemm

NAVSEAVADM Balisle

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Key Assets• Personnel (191 People)

– 141 Production (Foundry: 36, Machine Shop: 105)– 15 Manufacturing Engineering– 10 Business Office– 10 Quality Assurance– 9 Administration– 6 Facilities Engineering

• 80% working direct labor assignments

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Key Assets (cont.)• Foundry

– National Consolidated Naval Ships Foundry• the Navy’s only organic ships foundry• supporting emergent & hard to contract fleet requirements

– Among the largest non-ferrous pour capacities in the US (250K lbs.)

– Large lift/crane capacity– Furnaces ranging from 50 lbs. to 50 ton capacity– Significant centrifugal casting capability– Capable of providing most castable alloys

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Furnaces capacities from 50 lbs. to 50 tons

Misc. Small Furnaces 3000hz Furnaces

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Furnaces capacities from 50 lbs. to 50 tons

10 & 15 Ton Furnaces 50 Ton Furnace



Selected Products

Tin Bronze Strainer Plug Bronze Elbow



Selected Products

10” Gunmetal Elbow

1/2” Steel Valve Body



Key Assets (cont.)

• Machine shop– Only co-located foundry and numerically controlled (NC)

propeller machining facility in the US– 6 Large Scale Profilers

• (5) five-axis nc profilers– support monobloc machining up to 31 feet in diameter

• (1) five-axis nc profiler with dual spindle– supporting individual blade/part machining

– Automated Propeller Optical Measurement System (APOMS)

• The only one of its type • providing pioneering surface measurement technology



Propeller Machining Center



Propeller Machining Center– Automated Propeller Optical Measurement System (APOMS)



SU-15 High speed machine equipped with Linear motors


Naval Foundry and Propeller Center (NFPC)BUSINESS / TECHNICAL PARTNERS

NSWCCDR&D PROJECT MANAGEMENT

HYDRODYNAMIC DESIGNMANTECH

NORFOLK NAVAL SHIPYARD

COMMAND & OPERATING SUPPORTNAVSEA 05H

TECHNICAL AUTHORITY

NAVSEA PHL-SSES

INDUSTRIAL & HOST SUPPORT

UNITED DEFENSE

Minneapolis MN

PROPULSOR ASSEMBLY

PART MACHINING PROPULSOR TECHNOLOGY INC

Pittsburgh PA

TECHNICAL SUPPORT

INSPECTIONELECTRIC BOAT

Groton CT

SHIPBUILDERNFPC

ONR/DARPAADVANCED MANUFACTURING TECHNOLOGY

BABCOCK-WILCOX XT -Y12

Oakridge TN

PROTOTYPE MANUFACTURE

TECHNOLOGY TRANSFER

NAVSEA

HQ FUNCTIONS

PROGRAM OFFICES

PENN STATE ARL

State College PA

HYDRODYNAMIC DESIGN

MANTECH

CONCURRENT TECHNOLOGIES CORP.

NCEMT

Johnstown PA

FOUNDRY TECHNOLOGY SUPPORT

NATL. CENTER MNFCTRG SCIENCEAnn Arbor MI

COMMERCIAL TECHNOLOGYFOR MAINTENANCE ACTIVITIES



Technology Partnerships

• Key technology test bed– partners in developing and proving advanced manufacturing

concepts• MANTECH

• High Speed Machining (in partnership with UNC & NSWC)• APOMS upgrades, (with DOT 4)

– enhanced surface measurement• Propulsor Casting Process Improvement (in partnership with NSWC)

– reduced machining & welding• LASER Articulating Robotic System (LARS) (in partnership with PSU-ARL)

– low distortion, high quality welding

• Friction Stir Metal Processing (in partnership with ONR/DARPA/NSWC)


Naval Foundry and Propeller Center (NFPC)Summary

• NFPC is a unique facility, critical to the submarine industrial base

• NFPC is a Core Logistics Facility• Experienced in the manufacture and repair of

most of the Navy’s propellers/propulsors• NFPC can produce most any casting in almost

any material• Continuation and extension of strategic initiatives

will firmly position NFPC for the future– Partnerships– Development & Introduction of New Technology– Capital/Facility Investment

OverviewPurposeBackgroundBackgroundBackgroundChain of CommandKey AssetsKey Assets (cont.)Furnaces capacities from 50 lbs. to 50 tonsFurnaces capacities from 50 lbs. to 50 tonsSelected ProductsSelected ProductsKey Assets (cont.)Propeller Machining CenterPropeller Machining CenterTechnology PartnershipsSummary

Documents

DEFENSE MAINT SMP 04 - SAE InternationalMr. William Craig Norfolk Naval Shipyard Captain Joseph Campbell NAVSEA 04 RADM Klemm NAVSEA VADM Balisle. 29 SEP 04 Overview 7 Naval Foundry