Huntington Ingalls IndustriesOverview of Ingalls Shipbuilding: Industrial Application of

Composite Technology

14-15 MARCH 2013

Huntington Ingalls Industries (HII)Corporate Highlights

• Annual revenues of approximately $6.6 billion, backlog of more than $16.3 billion.

• Employees: more than 37,000; largest private employer in Mississippi and Louisiana, and largest industrial employer in Virginia

• Key Locations:

– INGALLS SHIPBUILDING• Pascagoula, MS – DDGs, LHAs, LPDs, Cutters• Gulfport, MS - Composite R&D, Composite Components• New Orleans, LA - LPDs, TAKRs, TAOs• Virginia Beach, VA - Fleet Support (AMSEC)• San Diego, CA - Fleet Repair & Support (Continental Maritime)

– NEWPORT NEWS SHIPBUILDING• Newport News, VA – CVNs, SSNs, RCOHs

The Nation’s Leading Military Shipbuilder

Surface Combatants

Amphibs

National Security Cutters

Fleet Support & Other

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HII-Ingalls ShipbuildingLocations & Products

DDG 1000

DDG 51LPD

NSC

LHA

Gulfport

CMSD 

Pascagoula

Avondale

AMSEC

• Annual Revenue: ~$3 billion• Employees: ~14,000 employees at

5 sites• Major Programs

– LHA– LPD 17– DDG 51– USCG National Security Cutter– DDG 1000 Deckhouse

Largest manufacturing employer in Mississippi and a major contributor to the economic growth of the state of Alabama 18

HII Ingalls Shipbuilding, Pascagoula

MS Spend 2010-2011Total - $219,865,138

4/2/2013

AdamsBolivarCarroll Clay Copiah DeSoto Forrest 242,557George Greene Hancock 12,267Harrison 12,350,107Hinds 510,011Jackson 198,283,970Jones 2,120,945Lafayette 33,895Lamar 48,050Lauderdale 2,709Lee 118,486Leflore 10,700Lincoln 2,179Lowndes Madison 3,017,867Marion 372,393Monroe Oktibbeha 97,308Panola Pearl River Perry Pike 22,375Pontotoc 87,761Quitman Rankin 635,922Smith Stone 1,384,444Tate Walthall Warren 3,063Winston 508,128

• 125 acre site

• 85 developed / 40 available

• Access to Gulf of Mexico

• Dredged depth – 12ft

• Height restriction – 95ft

• Location:

• 4 lane hwy to facility entrance

• 2.7 miles to Interstate 10

• 3.8 miles to Gulfport Intl. Airport

HII IngallsGulfport Composite Center of Excellence

Gulfport Center of ExcellenceCapability and Capacity

Capability• Composite materials provide innovative

solutions to mission system and structural design requirements extending capability beyond comparable metallic structures

• Unmatched capability to manufacture large scale marine composite structures; cored or non-cored with glass or carbon fiber cloth

• Successfully constructed world’s largest marine carbon fiber composite components for DDG 1000 Program

• Robust composite R&D capability for process and product technology advancement

Capacity• Flexible plant infrastructure able to support

multiple projects and project types

• Over 322,000 ft2 covered manufacturing space; 253,450 ft2 environmentally controlled

• Two flat panel molds capable of constructing single panels up to 8,000 ft2 each

• 7,500 ft2 of core construction tables

• All manufacturing bays equipped with bridge cranes – max lift capacity over 400 ton

A National Asset

Gulfport Center of ExcellencePeople and Processes

People• Only Department of Labor certified

Composite Apprentice Program in the United States

• All employees receive a minimum of three weeks training before entering the workforce

• Successfully hired, trained and assimilated over 600 employees into workforce between January 2009 and present

• Awarded OSHA Voluntary Protection Program (VPP) STAR certification for 2010 reflecting engaged workforce actively maintaining a safe workplace

Processes• VARTM, or Vacuum Assisted Resin

Transfer Molding

• Extensive ultrasonic non-destructive testing ability, including process development and qualification

• Quality checkpoints integrated into all work instructions

• Achieving near 4 sigma quality in carbon fiber flat panel and joint construction

• Process and procedural compliance verified at over 99% adherence

A National Asset

HII IngallsGulfport Composite Center of Excellence

Indexing LedgeIndexing Ledge•• Enable deckhouse Enable deckhouse and hangar and hangar deliverydelivery

WarehouseWarehouseEnvironmentally Environmentally controlledcontrolled30,000 sq30,000 sq--ftftSecured AreaSecured AreaOffices/Restrooms Offices/Restrooms

Bay 6 Assembly and Erection BayBay 6 Assembly and Erection Bay

Unit Assembly and Deckhouse Erection Unit Assembly and Deckhouse Erection 2 Unit Assembly Area2 Unit Assembly Area2 Deckhouse Erection Positions2 Deckhouse Erection Positions2 2 -- 225 Ton Bridge Cranes225 Ton Bridge CranesEnvironmentally ControlledEnvironmentally ControlledOffice/RestroomsOffice/RestroomsSmall Outfitting ShopSmall Outfitting Shop

LEGENDLPD Manufacturing

DDG ManufacturingUpgrades supporting DDG Program

Bay 2 TurnoverBay 2 TurnoverExpanded composite panel fabrication line Expanded composite panel fabrication line 120 Ton Turnover Crane120 Ton Turnover CranePanel turnover area for inspectionPanel turnover area for inspectionEnvironmentally ControlledEnvironmentally Controlled

Resin Storage and MixingResin Storage and MixingResin Storage Resin Storage Resin Mixing Resin Mixing QA Lab QA Lab

Bay 2 Bay 2 Bay 2 Extension Bay 2 Extension -- Assembly AreaAssembly Area157157’’ Building ExtensionBuilding ExtensionEnvironmentally ControlledEnvironmentally ControlledCrane CoverageCrane Coverage55--axis CNC Machining Centeraxis CNC Machining Center

Bay 2Bay 2Mold Tables Infusion AreaMold Tables Infusion Area2 2 -- 50 Ton Cranes50 Ton Cranes2 652 65’’x140x140’’ Mold TablesMold TablesEnvironmentally ControlledEnvironmentally Controlled

Bays 3 & 4Bays 3 & 4LPD Mast and R&D Infusion BaysLPD Mast and R&D Infusion Bays1 1 –– 40T & 140T & 1-- 50T Crane50T CraneEnvironmentally ControlledEnvironmentally Controlled

Bay 1Bay 1LPD Mast and R&D Assembly BayLPD Mast and R&D Assembly Bay2 2 –– 160 Ton Cranes160 Ton CranesEnvironmentally ControlledEnvironmentally ControlledCovered SlipCovered Slip

Bay 5 Core FabricationBay 5 Core FabricationCore Fabrication Core Fabrication 11-- 50 Ton Crane50 Ton CraneCore TablesCore TablesEnvironmentally ControlledEnvironmentally Controlled

Over $60M in Capital Improvements

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Leveraging Mississippi Assets

• University of Southern Mississippi– Economic Impact Assessment of Shipbuilding Plans– Market Analysis of Composite Opportunities– Composite Marketing Brochure Support

• MDA and MEDC– Multiple Introductions to Energy/Oil and Gas Opportunities

• Composite Blow Out Preventers, Hydrogen Storage Tanks, Wind Turbines, Digester Tanks etc.

• Mississippi Enterprise for Technology (Stennis Space Center)– Monthly Lunch and Learn

• Stennis Business Consortium– Quarterly industry meetings– Expo Events

Composite Applications

28 February 2013

Composite DeckhouseUSS Zumwalt

and joining it to a traditional shipbuilding processes

Making our own “steel”

Panel assembly Ship-shape unit Unit outfittingUnit integration

AEM/S MastLPD 17

1313

Max Launch Abort System (MLAS) Prototype Component Fabrication

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• Alternative launch abort system for Orion crew module supporting NASA’s Constellation Program

• Built to Aerospace design standards

– utilized complex shapes quality standards, and processes

• Used Marine materials and Labor for fabrication

– Labor rates significantly below Aerospace rates

• Adapted facility, workforce, and processes to meet design and manufacturing requirement

Image Source: NASA

(Fabricated at Ingalls)

(Fabricated at Ingalls)

(Fabricated at Ingalls)

VIDEO OF MLAS LAUNCH:http://www.nasa.gov/multimedia/nasatv/on_demand_video.html?param=http://anon.nasa-global.edgesuite.net/qt.nasa-global/ccvideos/larc/mlas-launch.mov&_id=undefined&_title=undefined&_tnimage=test.gif

Modifications Needed for Aerospace Fabrication

• Increase shop cleanliness – may require certification to ISO 14001 standards

• Upgrade and expand pre-preg capabilities– Autoclave, Fiber Placement equipment , Ovens, etc

• Align Engineering Aids and Manufacturing Execution System (MES) with aerospace requirements

• Personnel Training for required materials & processes

15 Image Source: NASA & Vistagy Software

Exploring Future Opportunities

History at Gulfport• (4) Composite Mine Hunters

• (75) Steel Barges (200ft ea)

• (1500) Assembly Units for Avondale

• Composites R&D

– Joint Modular Lightering System Barges

– ONR Composite High Speed Vessel Program

– DDG Topside Structures

– LHA Island Components

– Max Launch Abort System Demo (NASA)

– Aperstructures – Advance Antenna Integration

• CVN 77 Mast

• LPD Masts

• DDG 1000 Deckhouses

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Value Proposition• Ingalls Composite mechanic labor rates

lower than typical aerospace

• Ingalls has (aerospace & mechanical) engineers with aerospace experience

• Skilled craft workforce, capable of learning new processes

• Capability and capacity for parts ranging from small to very large

• Facility upgradable to meet Aerospace requirements

• Proximity to transportation options

Turbine Blades

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• Large, Complex Shapes

• Location accessible to Land-based wind farms

• Ideal location for offshore wind

• Growing market

• Subsidy dependent

• Potential for foreign Company partnership

Composites for Roadway Bridges

• Composite technology is mature, and worldwide use is growing

• Composite or hybrid-composite bridges are affordable and extend expected bridge life compared with traditional steel/concrete

• Manufacturing processes allow for modular, off-site production of components

– Reduces install time at bridge site– Lightweight panels and beams reduce demand

for heavy equipment required for fabricationKnickerbocker Bridge, Boothbay Harbor, Maine

Composite Bridge, Chicago

Light Weight Bridge Product

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Offshore Supply Vessels & Small Boat Market

• Vessels include:– Tugboats– Offshore supply vessels– Support vessels– Crew boats– Drilling rigs

• Provider of Supplies and spare parts through support services

Other Applications with a Composite Advantage:Waterfront

Submarine CamelShip Separators

Trench CoverPipe Camel

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Other Applications with a Composite Advantage:Rail Platform

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Ingalls Gulfport Approach

• Work with MDOT to assess need/demand for bridges within the state of Mississippi

• Team with MDA, University of Southern Mississippi, and compositebridge technology company (such as HC Bridge Co. or other TBD)

– Select three ideal locations w/in state– Each location to offer unique benefits/challenges for implementation– Develop design options for each location

• Work with MDOT and State of MS to acquire funding for selected bridges

• Fabricate and install composite bridge solutions at three MS locations