Expanded Adhesive Outfitting Applications - NSRP Burke-class destroyers ... Development of Technical Requirements for Expanded Adhesive Outfitting Applications Task 1 ... 406 Equipment

Cleared for Public Release – Distribution Unlimited

Expanded Adhesive

Outfitting Applications

March 10, 2015

All Panel Meeting


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

2

Cleared for Public Release – Distribution Unlimited 3

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


Previous NSRP Adhesive Outfitting Projects

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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


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


Update Implementation Plan for use of Adhesive Design Rules in Outfitting Applications


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


6 Quarterly Technical Review Minutes 12/18/2014



9 Draft Environmental and Survivability Test Plans 3/30/2015

10 Optimized Bonding Process Report 3/30/2015



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





20 Survivability Test Report 1/30/2016



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


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


Environmental Test Plans

Sample Environmental

Test Plates

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Before After

Modified

Tensile

Modified

Offset Shear Photos Courtesy of Click Bond


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


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


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


Bonding Materials

Photo & Drawing Courtesy of Click Bond


Identify Potential Process Improvements

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Flammable Solvent

Flammable Solvent Grind to Bare Metal

Flammable Solvents

Graphics Courtesy of Click Bond


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


Plans for Next Quarter

• Finalize Guidelines for Adhesive Bonding

• Develop Detailed Test Procedures

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Questions

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Documents

Expanded Adhesive Outfitting Applications - NSRP Burke-class destroyers ... Development of Technical Requirements for Expanded Adhesive Outfitting Applications Task 1 ... 406 Equipment