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Robotic Arc Directed Energy Deposition Additive Manufacturing for Shipbuilding (2019-375-004)

  • Robotic Arc Directed Energy Deposition Additive Manufacturing for Shipbuilding (2019-375-004)
Overview

Edison Welding Institute, Austal USA, Navus Automation,
NSWC-Carderock Division, NASSCO, HII Ingalls Shipbuilding

June 2019 – July 2021

INDUSTRY INVESTMENT: $1,315K | NSRP ASE INVESTMENT $1,315K

OBJECTIVE

This project’s overall goal is to develop a standardized robotic arc Directed Energy Deposition (DED) Additive Manufacturing (AM) gantry that can build a wide range of structures and components.

 

SUMMARY

This project will develop digital data workflow processes, establish workforce competencies, help break down process qualification barriers, demonstrate representative qualifications, and provide standardized equipment for robotic arc DED AM implementation.

 

KEY DELIVERABLES / BENEFITS

  • 50% reduction in time and 25% reduction in cost of DED AM Process Implementation
  • 33% ($1M) reduction in cost of Robotic Arc DED AM Gantry System vs. custom build
  • 53% reduction in Arc DED AM qualification costs

 

PROJECT RESULTS

 

The project established a large, prototype DED-AM capability (reportedly the largest in North America) and demonstrated operation through a number of large, complex fabrications.  This capability also demonstrated the workflow from CAD though robotic path planning, and facilitated training of shipyard members on its use.  The project also supported development of NAVSEA Technical Publication of Process Requirements for DED-AM, which was released near the end of the project and was applied to construction of a Phase 2 test article.   The project developed the design and specification for a future, shipyard-centric system deign for future implementation.

 

POINT OF CONTACT: Dennis Harwig | Edison Welding Institute | dharwig@ewi.org

 

Final Report approved for Public Release

  National Shipbuilding Research Program: Taking shipbuilding and repair to the next level NSRP is co-funded by the U.S. Shipbuilding Industry and U.S. Navy

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