Navy Metalworking Center Overview & Representative Projects

1. Navy Metalworking Center Overview & Representative Projects This presentation was prepared by the Navy Metalworking Center, operated by Concurrent Technologies Corporation, under Contract No. N00014-10-D-0062 to the Office of Naval Research as part of the Navy ManTech Program. Approved for public release; distribution is unlimited.

2. Operated by Concurrent Technologies Corporation • CTC is an independent, nonprofit, applied scientific research and development professional services organization. • 1,100 professionals; 50+ locations • More than 600,000 sq. ft., including 33,000 sq. ft. of lab space and 180,000 sq. ft. of high bay work/demonstration space • Top 100 Government Contractor (Washington Technology) • One of the World’s Most Ethical Companies (Ethisphere Institute) • Quality Standards: ISO 9001:2008 (Quality); ISO 14001:2004 (Environmental), AS9100 (Aerospace), CMMI ® Development Version 1.3 (Systems/Software Engineering); and OSHA VPP Star (Health and Safety)

3. NMC Overview • Provide for the development of metalworking manufacturing technology to meet the needs of selected weapon systems or Program Offices under industrial production and sustainment • Improve the affordability and mission capability of Navy systems by engaging in manufacturing initiatives that address the entire weapon system life cycle • Primary Focus: Implementation of technology

4. Focused Investment Strategy Affordability Initiatives Concentrate resources on few high-priority naval platforms for maximum benefit PEO (LCS) LCS PEO (JSF) F-35 PEO (Carriers) CVN 78 Class PEO (Ships) DDG 51 Class PEO (Subs) VIRGINIA ORP

5. Technical Areas • Materials characterization/testing • Process design and control • Product design and structural performance • Environmental issues and recycling • Information and data handling and transfer • Metals and advanced metallic materials • Metal-based composites • Ceramics • Metal/non-metal interface issues • Shape-making processes • Joining techniques • Surface and heat treatment • Primary metal materials manufacturing processes

6. Teaming Approach • Extensive use of Integrated Project Teams (IPT) in all NMC ManTech projects • Team members selected based entirely on having the “right” mix of technical skills and capabilities, regardless of company size

7. Project Development Process • ManTech project concepts come from several sources: • Ship and Aircraft Program Offices • NAVSEA and NAVAIR Technical Codes • NMC and Other ManTech COEs • Shipyards, Prime Contractors and DoD Contractors • Successful SBIR and STTR projects • Industry Partners, including Small Businesses • Projects are evaluated for: • Alignment with NMC Scope • Technical Maturity • Platform Support • Likelihood of Implementation • Return of Investment • Industry cost share / program office cost leverage is encouraged and is a factor in our project selection process

8. Representative projects by capabilities Metalworking Technologies At the heart of the Navy Metalworking Center’s work is improving metalworking technologies used in the construction of Navy weapons systems.

9. Indentifying Optimal Alloy 625 Formability • This project developed optimal forming practices for Alloy 625 in several critical CVN 78 components. Newport News Shipbuilding successfully implemented the practices developed in this project when forming these components. • Benefits • Minimize risk of cracking during forming of this costly material • Reduce schedule delays • Avoid costs to re-fabricate components CTC photo

10. Cold Forming of Alloy 625 Fittings NMC and the IPT confirmed that a closed-die, cold forming technique can be economically and successfully applied to large-bore, seamless Alloy 625 elbows on VCS and CVN piping systems.  • Benefits • Cost savings in excess of $500K for Alloy 625 fittings on CVN ranging in diameter from 2- to 8-inches. National Technical Systems photo

11. Waterjet Inlet Tunnel (WjIT) Manufacturing NMC explored alternative manufacturing processes to produce the WjIT entry edge for the Lockheed Martin LCS. A three-piece, near-net casting was developed and implementedusing advanced casting technologies. • Benefits • Reduced production cost • Reduced shipyard duration • 75% reduction in labor hours • 23% reduction in weld length • 30% reduction in weight • Improved geometric accuracy Marinette Marine Corporation photos

12. Development of Long-Length, Flexible, Vacuum-Jacketed Cryostats This project addressed cryostat configuration and manufacturing issues associated with fabricating long lengths of flexible, vacuum-jacketed cryostats. Cryostat multilayer insulation systems devised on the project using a standardized cryogenic test facility have been validated on five-meter-long test samples. ONR Program Code 33 photo • Potential Benefits • Cost savings and weight reduction

13. Improved Steel Casting Practices • Improved sand molding and molten metal pouring practices were developed and implemented at the NNSfoundry to significantly reduce casting defects • Benefits • $700K/yr cost savings • Reduced delivery time by up to 55 days for large steel castings Newport News Shipbuilding (NNS) photo

14. Optimizing Laser Peening for Navy Aircraft • An NMC project optimized the laser peening process for two Navy aircraft applications. The NMC project demonstrated and validated the potential of laser peening for improving the fatigue performance of these components. • Benefits • Improved fatigue and stress corrosion cracking resistance • Increased service life Metal Improvement Company photo

15. Electron Beam Direct Manufacturing Technology Demonstrator titanium structural components for the N-UCAS were manufactured using Electron Beam Direct Manufacturing technologies. In addition, lightweight aluminum spars and ribs were produced using advanced high speed machining. • Benefits • Acquisition cost avoidance • 35% weight reduction of affected parts Sciakyphoto

16. Titanium Components for M777 Lightweight Howitzer NMC developed and implemented novel manufacturing approaches to reduce part count and innovative forming technologies to reduce manufacturing cost and material waste in the construction of the M777 Lightweight 155mm Howitzer. The part count for the spade was reduced from 60 to one through near-net-shape casting. CTC photo • Benefits • As of February 2013, NMC’s project resulted in a nearly $68 million dollar savings for the 1,000 M777s that have been built.

17. Joining Technologies The Navy Metalworking Center is leading project teams to optimize several metal joining technologies for use in shipbuilding applications.

18. Low-Cost Friction Stir Welding (FSW) System • An NMC project developed a transportable, low-cost FSW system that produces stiffened aluminum panels by edge-welding extruded aluminum shapes. • Benefits • Significant cost savings through reduced capital, labor and scrap cost CTC photos

19. Expanded Capability for Low-Cost FSW NMC developed an enhanced friction stir welding (FSW) system for use on Joint High Speed Vessel (JHSV) product forms such as thick plate and hollow core extrusions. The system could reduce ship costs, improve welded joint quality, and decrease vessel weight. The project team also devised processes and tooling for JHSV products. Nova Tech Engineering image • Benefits • Capable of welding more product forms and sizes • Broader application throughout shipbuilding and other industries

20. Hybrid Laser Arc Welding of T-Beams An alternative manufacturing process using HLAW was developed to produce thin-sectioned HSLA-80 T-beams for DDG 1000 with minimal distortion. American Bureau of Shipping approved the procedure and Applied Thermal Sciences is qualified to manufacture HLAW T-beams in HSLA-80 and other steel alloys.  ATS photo • Benefits • 45% lower fabrication cost • $600K overall cost savings per DDG 1000 hull

21. Prototype Alternative Brazing System A prototype flame brazing system is addressing problems associated with manual flame brazing for CVN and VCS construction. Since June 2012, NNS has been using the brazing system in the construction of CVN 78. NNS has purchased three systems and intends to buy seven additional systems. CTC photo • Benefits • $2.6 million construction cost savings in the construction and overhaul of CVN and the construction of VCS • May benefit other platforms requiring flame brazing

22. Exothermic Welding for CVN An NMC project developed installation and repair procedures for exothermic (thermite) welding for Navy shipboard power applications. Newport News Shipbuilding will implement the procedures to complete installation of the Electromagnetic Aircraft Launch System on CVN 78 in the fall of 2013. Erico Products photo • Benefits • Reduced risk to quality and schedule • Reduced labor-hours for installation and maintenance • Increased system reliability and availability • Initiation of a fleet-wide process for splicing large diameter power cables

23. Improved Arc Cladding Procedure • An NMC project team developed a cladding procedure that optimizes hot wire Gas Tungsten Arc Welding (GTAW). The modified cladding process increases the deposition rate with equal or superior weld quality and low capital cost. Arc Applicationsphoto • Benefits • Capable of increasing deposition rate from 7.4 lbs/hour to 12.8 lbs/hour

24. Shipyard Processes The Navy Metalworking Center teams with shipyards to develop improved shipyard processes.

25. Mechanized Weld Removal System NMC developed a lightweight, portable tool that mechanically faces weld reinforcement on ship hull panels, substantially reducing the amount of hand grinding and associated injury claims, labor costs, and production costs. Implementation BIW is using the tools in DDG 51 and DDG 1000 construction. The system has also been adapted to perform back gouging of weld joints and is being used at BIW in DDG 1000 construction. BIW photos • Benefits • Weld shaving = $2.77M cost reduction for 3 DDG 1000 hulls

26. Environmental Control System in VCS Construction • An NMC project recommended an environmental control system to minimize lost workdays associated with painting. Implementation was originally planned on SSN 785, but partial implementation was expedited for SSN 782 construction in the summer of 2010. • Benefits • Nearly $300K cost savings per hull • Minimized lost workdays associated with environmental conditions falling outside of the specification CTC image

27. Improved Welding Procedures Prevents Overheating of Composite Joint Improved welding and cutting processes were developed to weld the shoes of the DDG 1000 deckhouse to the deck without exceeding the temperature limitations of the deckhouse composite. The processes developed were implemented at Ingalls Shipbuilding in July 2010. • Benefits • Reduced labor by 4,700 hours per ship by allowing the welding to be done in long increments rather than the 18 inches permitted by the previous procedure. • $840K total savings for the three ships in the class Ingalls Shipbuildingphoto

28. Optimization of Blasting Operations NMC is leading a project to improve the process for blasting submarine hull structures during new construction. The project team will optimize the blasting parameters to improve grit blasting efficiency and will develop more efficient ways to protect piping during blasting operations. Initial implementation is expected in 2012 for SSN 787. • Benefits • $350K savings per hull in reduced labor, materials, and disposal cost CTC photo

29. HSLA-80 Plate Distortion Mitigation BIW is modifying and evaluating changes to its handling of HSLA-80 steel plates as a result of an NMC project that investigated distortion issues with the plates to be used in the construction of DDG 1000. This project identified the potential root causes for the distortion and determined revisions for future procurement specifications for HSLA-80 plate. • Benefits • Cost avoidance in production BIW image

30. Pipe Preparation and Welding Tools This project developed pipe fitting tools that reduced the manual pipe preparation and welding labor of small diameter pipe details on VCS. Several inspection and welding tools identified by NMC are in use at the Electric Boat and Newport News Shipbuilding. CTC photo • Benefits • Prototype pipe fixture and alignment clamping tools demonstrated a reduction of 2,400 labor-hours/hull ($168K) • Reduced fatigue demonstrates an additional 1,000 labor-hours/hull reduction

31. Web-based Welding Procedure System NMC developed a Web-based welding procedure system to reduce rejection rates of vendors’ submitted procedures. Newport News Shipbuilding and Electric Boat implemented the software tool in 2010 WeldQC, Inc., image • Benefits • Reduce the rejection rate of vendors’ procedures from 90% to 20% • $1.65M annual savings from vendor and shipyard savings alone

32. Plate Edge Preparation Improvements An NMC project identified and developed concepts for mechanized abrasive tools to remove light surface rust and primer from the edges of large plates. In 3Q FY 13, BIW implemented the developed prototype system; full implementation with commercially produced tools is expected in 4Q FY 13. BIW photo • Benefits • Potential 200% or greater increase in production rate • $4.5M savings per DDG 1000 hull • $2.5M savings per DDG 51 hull

33. Advanced Metallic Materials The Navy Metalworking Center is improving Navy ships through the development and improved processing of advanced metallic materials.

34. HSLA-115 Evaluation and Implementation NMC led a project team in the development of HSLA-115 steel, which provides increased yield strength with good toughness. Construction of CVN 78 began with HSLA-115 material in December 2009. More than 2,000 tons of HSLA-115 have been procured and delivered for CVN 78. ArcelorMittal photo • Benefits • Acquisition cost avoidance • 132 long tons of topside weight savings on CVN 78

35. Development of Corrosion-Resistant Components • This project developed a modified 15-5PH corrosion-resistant steel to replace K-Monel® in several critical components in the torpedo tube muzzle door operating linkage of Navy submarines. The project also developed critical forging and heat treating parameters that will result in material properties tailored for this specific application. Implementation will start with VCS new construction and retrofit existing components on other classes in FY14. • Benefits • $9.4M cost savings over the remaining life of 70 in-service hulls • Material cost savings • Mechanical improvements CTC photo

36. Design for Manufacturability The Navy Metalworking Center uses a design for manufacturability approach when evaluating the manufacturability of components and assemblies.

37. Improved Manufacturing of Advanced Gun Systems This project successfully reduced manufacturing cost and weight for the DDG 1000 Advanced Gun Systems (AGS) through various manufacturing improvements. • Benefits • $5.3M per hull manufacturing cost reduction • Reduced system weight that will improve safety and survivability functions CTC photo

38. Improving Producibility of Weapons Cradles • This project is using Lean Manufacturing and Design for Manufacturability (DFM) principles to identify opportunities for improving the producibility of the submarines’ weapons cradles. The cradles have a long, thin shape and complex fabrication and application requirements, which create construction challenges. U.S. Navy photo • Benefits • 10% reduced rejection rate and rework • $612K to $1.2M cost savings per hull

39. LASCOR Panel Evaluation and Implementation This project optimized the LASCOR (LASer-welded corrugated-CORe) design for materials, manufacturability, joining, structural and protection performance, weight and cost. The technology has been implemented into the Deck Edge Safety Berms and Personnel Safety Barriers on DDG 1000. • Benefits • Reduced weight and cost • Less distortion • Corrosion resistance Berms PSBs

40. Coatings Application and Removal Determining the optimum coatings application and removal process, as well as what surface treatment to use, can have a large impact on a weapons system’s performance.

41. Alternative Materials / Application of Hull Treatment This project evaluated various aspects of the DDG 1000 hull treatment system in an effort to reduce the cost for procurement, installation, repair, and decommissioning of hull treatment. Several recommendations are being incorporated in the development and modification of hull treatment specifications. • Benefits • $3.5M per hull cost reduction CTC photo

42. Alternative Damping Materials • This project found alternative materials and installation methods for damping tile on VCS. The IPT down-selected pressure-sensitive adhesives and are currently evaluating performance to verify they meet the requirements for this application. It is expected that the results of this project will be implemented on SSN 786 in 2012. NNS photo • Benefits • Estimated $700K cost savings per hull.

43. Q & A For more information, contact: Dan Winterscheidt 814-269-6840 winter@ctc.com