Objective:
Develop and implement a Weld Shrinkage and Distortion Control Process, methodologies, and enabling technologies within the U.S. shipbuilding and repair industry through the use of predictive models, data interface solutions, and shrinkage model CAD Plug-ins.
Summary:
The project team collected shrinkage measurements on 55 production and test panels at the participating shipyards – 37 uniform panels and 18 complex panels. Shrinkage models were then developed through regression analysis of the panel data. Finally, an excel-based interface was developed that will calculate predicted shrinkage values based on user input of production variables such as material type, weld process, and location of butt and stiffener welds.
While the tool is customized for the range of panels used by the project team members, the project developed a desk guide which allows an interested organization to replicate the data collection and model development process for their material set.
Implementation at participating shipyards is on-going. For example, Bollinger Shipyards is making progress towards “Neat Construction” on their USCG Fast Response Cutter new building program by including predicted weld shrinkage values in their 3D product models. Improvements in the shipyard’s accuracy control program and focused training of welders, fitters and engineers are additional steps that Bollinger is taking on their path towards neat construction.
Key Deliverables / Benefits:
Request Final Report from NSRP – Limited Distribution authorized to U.S. shipyards and NSRP ASE Program representatives
Point of Contact:
Brent Tompkins, Bollinger Shipyards
Overview
Project Team:
- Bollinger Shipyards
- Ingalls Shipbuilding
- Marinette Marine
- Vigor Industrial
- Hepinstall Consulting Group
- Victoria Dlugokecki
- Gatekey Engineering
- ShipConstructor Software USA
- Edison Welding Institute
May 2010 - December 2012
NSRP ASE Investment: $1.9M
Industry Investment: $2.0M