Project Number: S3006

Project Title: Large Scale Monolithic Machining for Naval Applications

Period of Performance: MAY24 – MAY27

Structural assembly in ship building is facing growing challenges due to dependence on heavily manual welding operations. An expanding workforce and new products force a steep learning curve to contend with the material property challenges and limitations of this fabrication process. With roughly eighteen percent of all submarine manufacturing hours spent welding, deficiencies in the process can become a bottleneck for all downstream customers. Variation due to human factors, long set up times and extensive testing requirements often lead to cost overruns on small volume production of complicated subassemblies. With growing demands as a result of COLUMBIA (CLB) and Virginia Payload Module (VPM) reaching full production, new methods need to be proven to accelerate production and meet first time quality demands.

The objective of this Center for Naval Metalworking (CNM) project is to twofold: (1) prove feasibility for monolithic machining principles in shipbuilding and (2) provide design tenets for future monolithic manufactured parts. Due to the large variety of potential candidates, a representative sample of parts must be chosen that can demonstrate future capabilities. The final deliverable will include monolithically machined prototypes of varying size, geometry and material properties. Success will be measured by the ability to reduce cycle times, distortion and other key performance indicators.

By investigating historic data, utilizing subject matter experts and absorbing industry best practices the selected articles will be redesigned, tested and proven to enhance future manufacturing decisions as it relates to cost and schedule considerations. This proposed solution aims to reduce labor hours associated with welding and fitting, install cycle time and open new opportunities for novel article design for the monolithic welding process resulting in an estimated combined 5-year savings of $7,887,535 and ROI of 1.01 across the VA, CLB, and VPM platforms.

Describe the results of the project and the benefits to be accrued by the implementing activity and/or the platform / weapon system. In the case of completed implementation, specify the benefits that have already been realized. Quantitative and/or qualitative benefits may include cost reduction, cost avoidance, reduced cycle time, and/or improved capability. Information presented could include cost reduction per platform / weapon system (with the total number that will utilize the technology), percent weight reduction per component or platform / weapon system and any associated cost reduction, environmental compliance, etc. Quantify the benefits whenever possible. Include the specific impact(s) the results of this project have had or will have on the warfighter. With current Navy ManTech Program emphasis on affordability, it is expected that the majority of new Success Stories will focus on cost-reduction benefits.

GDEB shall provide an implementation plan incorporating all design tenets, production parts and recommendations for future machine requirements discovered over the course of the project. This will include revisiting the component selection matrix and determining all necessary capital, facility, and IT improvements to scale the application of monolithic machining across Groton, Quonset Point and Focus Factory sites.