Expanded Adhesive Outfitting Applications - NSRP Burke-class ... Requires separate bonding /...

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Expanded Adhesive Outfitting Applications June 16, 2015 Ship Design and Material Technology Panel Meeting

Transcript of Expanded Adhesive Outfitting Applications - NSRP Burke-class ... Requires separate bonding /...

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Expanded Adhesive

Outfitting Applications

June 16, 2015

Ship Design and Material Technology

Panel Meeting

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Presentation Outline

• Status of Previous NSRP Adhesive Outfitting Efforts

• Update: Expanded Adhesive Outfitting Applications

– Deliverables From Last Quarter

• Draft Environmental and Survivability Test Plans

• Optimized Bonding Report & Procedure

– Activities for This Quarter

• Task 5: Finalize Guidelines for Selecting Adhesive Bonding Applications

• Task 6: Develop Detailed Test Procedures for Phase II Tests

• Plans for Next Quarter

• Summary & Closing

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Ingalls Shipbuilding

• Building four classes of ships simultaneously—

nine ships now in production

• Won a contract in June 2013 to build 5 additional

Arleigh Burke-class destroyers

• Builder of record for LPD and LHA classes of

amphibious assault ships

• Builder of largest multi-mission National Security

Cutter for the U.S. Coast Guard

DDG 51 Surface Combatants LPD 17 Class Amphibious Transport

USCG National Security Cutter

LHA 6 Amphibious Assault Ship

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Previous NSRP Adhesive Outfitting Projects

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NSRP Panel Projects: Cost Reduction Measures for Local Cable Hanger Installations (SCRA 2012-439)

Cost Reduction Measures for Late Stage Outfitting (SCRA 2012-467)

Status Update: Adhesive Outfitting Approved on LPD Class Ships The LPD Contract has been modified to reference adhesive bonding in the relevant Specification Sections. Applies to: Compartments that are “signed off”, completed, or adjoining spaces, or adjacent to completed tanks

Items: Local cable runs and small boxes Deck berthing and furniture foundations

Bulkhead foundations

Limits: Repair, replacement, or relocation only Approved substrate only Approved Adhesive only Requires separate bonding / grounding Height restrictions Wire way hanger rules Requires NAVSEA approved bonding procedure

This approval is a starting point which leaves plenty of room for expansion with experience and better data.

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Expanded Adhesive Outfitting Applications

Objective:

To expand applications for adhesive outfitting beyond specifically tested

and approved items by developing allowable load limits and design rules

for adhesively bonded studs

Technical Approach:

– Determine failure loads through shock and vibration tests

– Qualify adhesives through environmental tests

– Follow NAVSEA adhesive guidelines

– Establish design rules and identify any changes to ship specifications

required for implementation

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Team Members

• Ingalls Shipbuilding – Project Lead

– Sean Murphy, Jarrod Gilmore, Mark Losset, John Walks, Ronnie Romero, D G

McMillion

• Bollinger Shipyards

– Dennis Fanguy, Barry Matherne

• National Technical Systems

– Mike Poslusny, Tucker Thompson, Conner Smith

• SCRA

– Mary Saady, Project Manager

• NASSCO

– Dan Sfiligoi, Project Technical Representative

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Team Member Roles

Ingalls Bollinger NTS

Project Initiation Lead Support Support

Develop Requirements Matrix Lead Support Support

Develop Environmental and Survivability Test Plans Lead Support Support

Optimize the Adhesive Bonding Process Lead Support Support

Finalize Guidelines for Selecting Adhesive Bonding Applications Lead Support Support

Develop Detailed Test Procedures for Phase II Tests Lead Support Support

Execution of NAVSEA Approved Testing and Development of Implementation Requirements

Lead Support Support

Prepare Test Articles and Conduct Environmental Tests Co-Lead Support Co-Lead

Conduct Survivability Tests Support Support Lead

Develop Recommended Changes for Mounting Applications and Specification Requirements

Lead Support Support

Update Implementation Plan for use of Adhesive Design Rules in Outfitting Applications

Lead Support Support

Project Management Lead Support Support

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Project Work Breakdown Structure (WBS)

Phase I: Development of Technical Requirements for Expanded

Adhesive Outfitting Applications

Task 1…..Project Initiation

Task 2…..Develop Requirements Matrix

Task 3…..Develop Environmental and Survivability Test Plans

Task 4…..Optimize the Adhesive Bonding Process

Task 5…..Finalize Guidelines for Selecting Adhesive Bonding Applications

Task 6…..Develop Detailed Test Procedures for Phase II Tests

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Project Work Breakdown Structure (WBS)

Phase II: Execution of NAVSEA Approved Testing and

Development of Implementation Requirements

Task 7.….Prepare Test Articles and Conduct Environmental Tests

Task 8…..Conduct Survivability Tests

Task 9…..Develop Recommended Changes for Mounting Applications and

Specification Requirements

Task 10….Update Implementation Plan for use of Adhesive Design Rules in

Outfitting Applications

Task 11….Project Management

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Milestone Schedule – Phase I

Milestone Title Due Date

1 Project Management Plan 9/18/2014

2 Quarterly Report 9/20/2014

3 Kickoff Meeting Minutes 9/30/2014

4 Requirements Matrix Report 11/25/2014

5 Quarterly Report 12/18/2014

6 Quarterly Technical Review Minutes 12/18/2014

7 Quarterly Report 3/20/2015

8 Quarterly Technical Review Minutes 3/30/2015

9 Draft Environmental and Survivability Test Plans 3/30/2015

10 Optimized Bonding Process Report 3/30/2015

11 Quarterly Report 6/20/2015

12 Quarterly Technical Review Minutes 6/30/2015

13 Final Environmental and Survivability Test Plans & Procedures 6/30/2015

14 Guidelines for Adhesive Bonding Applications 6/30/2015

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Milestone Schedule – Phase II

Milestone Title Due Date

15 Phase II Kickoff Meeting Minutes 7/30/2015

16 Quarterly Report 9/20/2015

17 Quarterly Technical Review Minutes 9/30/2015

18 Quarterly Report 12/18/2015

19 Quarterly Technical Review Minutes 12/18/2015

20 Survivability Test Report 1/30/2016

21 Quarterly Report 3/20/2016

22 Quarterly Technical Review Minutes 3/30/2016

23 Environmental Test Report 3/30/2016

24 Updated Implementation Plan 4/30/2016

25 Final Project Report 5/20/2016

26 Final Technical Review Minutes 5/30/2016

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Activities this Quarter

Task 5 - Finalize Guidelines for Selecting Adhesive Bonding Applications

Task 6 - Develop Detailed Test Procedures for Phase II Tests

Request Approval of Phase II Funding

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Deliverables from Last Quarter

• Draft Environmental and Survivability Test Plans

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Environmental Test Plan

The test plan is designed to measure bond performance under a variety of

conditions outlined by NAVSEA. The main parameters are:

• Test Plates - Steel, Aluminum, Corrosion Resistant Steel (CRES) Honeycomb

• Bond Strength - Tensile and Shear

• Adhesives - Plexus AO420 and Click Bond CB200

• Attachments - Studs, Click Bond CB3200

• Conditions - Baseline, Corrosion / Aging, Elevated Temperature

• Variability - Lot to lot based on 3 lots

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Environmental Test Plans

• Test Plates – 5 Replicates per Plate

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Steel, Aluminum, Corrosion Resistant Steel (CRES) Honeycomb

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Environmental Test Plans

• Bond Performance – Tensile and Shear

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Modified

Tensile

Modified

Offset Shear

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Environmental Test Plans

• Environmental conditions:

– Baseline: Room Temperature Dry (simulates interior, conditioned spaces)

– Corrosion / Aging: Extended exposure in salt fog and elevated temperature

– Fluid Immersion: Extended exposure at elevated temperature (water, cleaning fluid,

lubricating oil)

– Elevated Temperatures:– Adhesive upper limit and elevated temperature corresponding to

an N-30 class boundary backside thermal rise)

– Curing Times: Curing curve at lower and upper application temperature limits

• Specific procedures / methods for fabricating test plates, bonding studs, and

performing are included in the plan or appendices.

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Survivability Test Plan

Overall Shock Test Series Objective

• The main objective of all the shock testing is to determine the shock

adequacy of various adhesive mounted stud configurations. This

objective can be broken into 2 main categories:

– Test various configurations to failure to determine the typical failure modes of the

adhesively mounted studs during shock.

– Test various configurations per the standards of MIL-S-901D for shock approval

• In general, the test series are developed to mitigate the risks of the

numerous variables that are involved in stud mounted equipment.

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Survivability Test Plan

LWSM Test Description

• The LWSM test series will be performed for adhesive mounted stud configurations consisting of one and two studs up to the weight limits of the shock machine.

• Series A will test the test specimens to failure to determine the weight capacity and failure mode. Multiple specimens will be tested to ensure repeatability and reduce the affects of any anomalies in the testing or fabrication of the specimens.

• The stud will be adhesively mounted and tested with a baseline weight. After the initial three blows in one direction, the weight will be increased and the third blow will be repeated. The weight will continue to be increased until a failure occurs.

• This process will be done in both the top and back directions. These failures will help Shock Engineering determine the failure mode of each adhesively mounted stud.

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Survivability Test Plan

LWSM Test Description

• This figure is an example of the

dummy weight fixture that will be used

on the single stud test specimens. A

similar approach will be used on the

two stud configurations. Test

specimen studs will be attached using

standard manufacturing guidelines.

The full details of the adhesive

manufactured guidelines will be

included in the detailed Series A and

Series B Test Procedures.

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Single Adhesive Mounted Stud Test Dummy Weight

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Survivability

• Shock Test Plan and LWSM

Test by Ingalls

• Shock Test requirements

defined by Mil-S-901D

• Test Approach:

– Ranging Tests (single panel)

– Certification Tests (duplicate

panels)

– Repeat with multiple

substrates

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LWSM at Ingalls

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Survivability

• Vibration Test Plan by

Ingalls and NTS

• Vibration Tests at NTS

Facility

• Test requirements defined

by Mil-S-167-1

• Test Approach:

– Cut Test Articles from Shock

Test Plates

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Vibration Table at NTS

Photo Courtesy of NTS

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Deliverables from Last Quarter

• Adhesive Bonding Optimization Report & Bonding Procedure

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Example Click Bond Installation Procedure

Instructions Courtesy of Click Bond

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Adhesive Bonding Process Optimization Report

This study and report was proposed for the following reasons:

– Certain bonding tests have produced variable results possibly due to differences

in the procedures used.

– Better guidance is needed to select the proper surface preparation method for

individual substrates.

– Better documentation is needed for bonding materials and process steps

– Lessons learned from previous installations shipyard experience needs to be

captured and communicated.

– NAVSEA requested that a shipyard document the procedure in a controlled

document.

This report will build on previous work to document the knowledge and lessons

learned from previous programs. The objective is to produce a comprehensive

Adhesive Stud Bonding Procedure.

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Adhesive Bond Process Optimization Report

• The discussion section will cover each step in the bonding process flow from

beginning to end as shown below. Materials and operations will be discussed

with respect to their suitability for shipboard installation and potential

alternatives.

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Step 1. Assemble Materials Step 2. Verify Conditions Step 3. Solvent Wipe Stud Base Step 4. Solvent Clean and Abrade SubstrateStep 5. Prepare AdhesiveStep 6. Apply Adhesive and Install Stud

Adhesive Bonding Process Flow

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Highlights from Optimization Study

Adhesives

• Potential issues with these adhesives are that they are flammable in the

uncured state, they have a strong odor, they have very short working time in

hot conditions, and they have limited shelf life unless stored under

refrigeration. The project team discussed these topics and concluded they

were not a major issue for current shipboard installations.

• While newer methacrylate adhesives have been developed to address these

potential issues, the team determined that there was no reason to pursue

them until a specification for qualifying the existing adhesives was developed.

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Highlights from Optimization Study

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Abrasives

• Abrasives are used to prepare the surface for adhesive bonding. The main

objective in this report is to provide improved guidance on the types of

abrasives and where they are used. This incorporates lessons learned from

experience with test programs and training information provided by Click

Bond. The section on Cleaning and Abrading will provide additional guidance

on how the abraded surface should appear.

Rigid A24R WheelAl. Oxide Hand

Sanding PadDiamond Hand

Sanding Pad36 Grit Fibre Disc

Abrasive Materials Used for Surface Preparation

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Highlights from Optimization Study

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Non-Flammable Solvents

• Approved cleaning solvents are flammable and require special handling.

Shock tests were conducted to compare the performance of two non-

flammable cleaning solvents. The chart below shows that they did not

consistently perform as well. They will not be carried forward into the full

environmental and survivability test programs.

Light Weight Shock Test Showing Score Based on Load at Failure

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Highlights from Optimization Study

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Secondary Surface Preparation

• Variation in bond strength is most commonly due to inadequate surface

preparation. The approved procedure language for painted steel specifies:

– Abrade with 36 grit fiber disc

– “PAINTED STEEL SUBSTRATE shall be prepared to Society for Protective Coatings

(SSPC) surface preparation Standard SP-11. This is a visual standard requiring a minimum

1 mil. surface profile.”

Good - Rough Bad - Polished

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Task 5 - Finalize Guidelines for Selecting

Adhesive Bonding Applications

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The project seeks to document and consolidate the various

guidelines that have been proposed for the use of adhesive

bonding.

• NAVSEA has issued reference documents which provide a

baseline set of guidelines.

• NAVSEA provided a template for adhesive use in conjunction

with the project Requirement Matrix Discussions

• NAVSEA directed certain restrictions in the LPD contract

modification.

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NAVSEA Source documents (restricted distribution):

• Use of Adhesively Mounted Studs in Naval Applications (Carderock,

2011)

• Fire Performance Requirements for Adhesively Bonded Studs Used to

Mount Furniture Items to Ship Boundaries (NSWCCD-61-TM–2006-19)

Task 5 - Finalize Guidelines for Selecting

Adhesive Bonding Applications

The goal is to negotiate a set of guidelines with no distribution restrictions and get NAVSEA signoff

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Task 6 - Develop Detailed Test Procedures

for Phase II Tests

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Development of the detailed test procedures required to

execute the Environmental and Survivability test plans are

underway and expected to be complete by June 30, 2015.

The Adhesive Bonding Procedure, which will be used to

prepare test articles is complete and has been approved by

NAVSEA.

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Request Approval of Phase II Funding

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The remaining Phase I deliverables are:

• Adhesive Bonding Guidelines

• Detailed Test Plans and Procedures

Upon submission of these reports (by June 30, 2015), the

project team will request approve of Phase II funding.

Phase II tasks include preparation of test articles, conducting

tests, analyzing results, and preparing recommendations for

implementation.

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Plans for Next Quarter

• Kick-off Phase II

• Task 7 - Prepare Test Articles and Conduct Environmental Tests

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Questions

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