Project Number: S2904

Project Title: Multi-Function Shipbuilding Robot

Period of Performance: APR21 – JUL25

The current weld process to manufacture vertical and horizontal erection joints requires scaffolding and suspending craftsmen to initially prepare weld joints, perform the weld and inspect the welded joint seam. This process is time-consuming and requires multiple departments and resources to support production and erection.
Current mechanized welding processes utilize a track welding system. The tracks have standard lengths and require multiple sets of magnets to secure the tracks in place. Huntington Ingalls Industries – Ingalls Shipbuilding (Ingalls) also requires the use of temporary tabs to be welded from the track to the unit as an additional safety measure. Installing this track for a single welding seam becomes cumbersome, and all of the tasks require the use of either scaffolding or boom lifts, increasing manufacturing costs.
This Center for Naval Metalworking (CNM) project will take advantage of the recent emergence of several technologies and develop a foundation for the implementation of automated robotic procedures for the surface preparation, welding, interpass cleaning and inspection, and final inspection required for vertical and horizontal erection joints. The overall multi-function shipbuilding robot will be developed using a phase-based approach. Phase I establishes the requirements for each of the desired processes and researches the available technologies on which the system foundation can be based. Phase II focuses on implementing the automated robotic welding processes and utilizing the foundation of a trackless portable robot. A follow- on project will be developed to expand the functionality of the base robotic system. Phase III will focus on developing the capability for surface preparation by the robot to automatically perform welding preparation and interpass cleaning. Phase IV will add the capability of in-process and final inspection to the overall multi- function robot capability. Ultimately, the final system will provide an implementable, automated multiple-function robot solution that minimizes scaffolding needs and decreases the required craft labor to support the welding of erection joints.

Ingalls anticipates this effort will reduce the labor hours and resources required to erect scaffolding and track welding set up and decrease the labor hours needed to weld erection joints by 50 percent. Implementation of the multi-function shipbuilding robot is estimated to result in savings of $668.0K per DDG hull. This results in potential five-year savings of $3.34M for DDG or $6.305M for Ingalls’ combined platforms.

The project results will be implemented at Ingalls’ Pascagoula, MS, facility across the DDG, LHA, LPD and NSC platforms. Implementation is anticipated to occur in the first quarter of FY2026.