Objective:

This project builds off a prior NSRP RA project (2019-375-004) on Robotic Arc Directed Energy Deposition (DED) Additive Manufacturing (AM) for Shipbuilding that established DED testbed systems and expertise, demonstrated manufacturing qualification requirements, and demonstrated high quality builds and component prototypes. Concurrently, NAVSEA and ABS published requirements for DED manufacturing:

  • NAVSEA Technical Publication S9074-A4-GIB-010/AM-WIRE DED – Requirements for Metal Directed Energy Deposition Additive Manufacturing, May 27, 2021
  • ABS Guide for Additive Manufacturing, April 2021

Using these new standards, this project will develop NAVSEA and ABS approved process-material design data (major gap), establish prototype quality management processes that are compliant with new requirements, qualify procedures and DED manufactured parts, and establish a commercial source for DED manufacturing and repair of marine components. In addition, this project will develop advanced DED support processes (build solvers, sensors, and controls) for high duty, lights-out systems to maximize business case

Summary:

  • Phase 1
    • In collaboration with ABS and NSWCCD, create the dual ABS/NSWCCD Manufacturing Qualification Plan
    • Install the DED-AM system at commercial vendor site
    • Create Nickel-Aluminum Bronze (NAB) Standard Qualification Builds (SQBs), NSWCCD defined material selection requirements for NAB DED, and ABS and NSWCCD provided SQB-PQTR (Process Qualification Testing Requirements) for approval.
    • Create the Quality Management System (QMS) Process Framework and SOPs for DED Manufacturing Requirements and obtain NSWCCD/ABS approval
  • Phase 2
    • Demonstrate operation of the CLOOS Robotic DED-AM system with production of first article and full-scale prototype LCU propeller
    • Develop and provide Advanced Robotic Arc DED CAM and DMCS (Dimensional Management Control System) Training
    • Host a robotic DED manufacturing and repair workshop with demonstrations of process and equipment for NSRP shipyards and other industry attendees
    • Summarize the results in an overall final report

Key Deliverables / Benefits:

This project will:

  • Develop, transition, and implement robotic arc DED manufacturing and repair of marine components
  • Acquire design approval for nickel aluminum bronze (NAB) DED materials for marine components
  • Develop and implement ABS and NAVSEA compliant quality processes and standard operating procedures (SOPs) for DED manufacturing and repair implementation
  • Improve DED productivity and affordability through advanced computer aided manufacturing (CAM) solvers, sensors, and controls; build a qualified prototype propeller and/or other qualified components
  • Host annual shipyard workshops to transition technology and business processes to NSRP shipyards and Naval stakeholders.

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Overview

Information, Design, & Integration

Project Team:

  • EWI, Vigor Shipyards, Ingalls Shipbuilding, Wildcat Propellers, Ohio State University, Navus Automation, ABS, Design Software International, NSWC Carderock

April 2023 – May 2026

INDUSTRY INVESTMENT: $1,190K | NSRP INVESTMENT: $1,189K

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