Objective:

The objective of this project is to complete and document the implementation of the Hybrid Induction Arc Welding (HIAW) system that was developed in a previous project (2013-452) in production at Bollinger Shipyards.

Summary:

This project replaced the existing panel line Series Arc Welding system with a Hybrid Induction Arc Welding (HIAW) system on the Ogden gantry one-sided seam welder at the Bollinger Lockport facility. Inspection showed that the gantry and plate hold-down system was capable of utilizing the HIAW process for butt-welding of plates. The overall approach was designed to facilitate future installations by significantly reducing the risk to other shipyards. In addition, testing of the resultant welds provided a significant added understanding of this new process that serves to reduce the risk of implementation. Shipyards that wish to proceed with their own HIAW systems will have the information collected during this project to aid with procedure development and process approval from ABS or NAVSEA. The information was into an Implementation Guide to be published and available through EnergynTech and NSRP.

The primary project goal was to provide a level of assurance that the process can:

  • Successfully operate and produce sound welds in a production environment; and,
  • Meet the necessary requirements for ship production operations

Through the experience of using the process in production, this installation at Bollinger has met that goal.

Benefits of this project include:

  • An opportunity to see the process successfully implemented and operating in another shipyard
  • 20% Reduction in Weld Straightening effort
  • 20% Reduction in Fit-Up Costs
  • 15% Reduction in Rework Cost
  • Increased Technology Readiness Level (TRL) for both thick and thin Butt Joint Welds

Request Final Report from NSRP– Distribution Authorized to Project Participants and NSRP ASE Representatives

Overview

Ship Production Technologies

 

Project Team:

  • Bollinger Shipyards
  • EnergynTech
  • Electric Boat
  • Ingalls Shipbuilding
  • GD Bath Iron Works
  • Gunderson Shipbuilding
  • Gatekey Engineering
  • Miller Electric and Hobart Companies
  • Vigor Shipyards

April 2016 – April 2017

INDUSTRY INVESTMENT: $1.52M

NSRP ASE INVESTMENT: $1.41M

GOVERNMENT PARTICIPANTS: $50K

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