Overview
Development of HiDep Welding Process for Butt and T-Fillet Joints Implementation Phase (2016-436)
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
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
KEY DELIVERABLES:
Request Final Report from NSRP– Distribution Authorized to Project Participants and NSRP ASE Representatives
POINT OF CONTACT:
Brent Tompkins, Bollinger Shipyards