Overview
Project Number: S2918A
Project Title: Sustainment Technology Insertion Assessment
Period of Performance: JUN21 – JAN22
Objective
Technology development and insertion is a key enabler of improving the efficiency and effectiveness of many existing shipyard production processes. The goal of this project was to evaluate key repair technologies that have previously been proven to improve repair processes at public Navy repair shipyards, and to identify the feasibility and requirements for transition of the technologies into production within a private naval repair environment.
The objective of this project was to investigate two key repair technologies, 3D laser scanning and cold spray metallic repair. For each technology, a feasibility study was completed to identify the technical, economic, and operational challenges and opportunities relative to utilizing these technologies in a private repair shipyard.
Benefits/Payoff
This special project feasibility assessment was accomplished over a short 7 month duration. The project team began by reviewing previous PSU-ARL led efforts in the areas of 3D laser scanning and cold spray. Ingalls hosted a shipyard tour with the IPT to brainstorm potential use cases.
A potential 3D laser scanning vendor, FARO, traveled to Ingalls and completed a demonstration of their latest hardware and software capabilities and costs. A process improvement discussion was also held pertaining to best practices and scanner settings in order to obtain faster scanning times.
The IPT traveled to Puget Sound Naval Shipyard and met with the Planning Yard Innovation (PYI) team to discuss 3D laser scanning. Benchmarking was performed on hardware and software. Common issues were identified pertaining to data transmission, data storage, and scanning electrical cable tags. The PYI also shared their current process of “snipping” scan pictures and inserting them into ship alteration drawings.
The IPT also traveled to Norfolk Naval Shipyard to evaluate the MARS cold spray unit. The MARS is a multifunctional automated repair system that is portable and can blast an area prior to cold spray application.
The team compiled all the data and information collected to produce a comprehensive feasibility report for each technology. For 3D laser scanning, a positive business case was identified for investing in the latest technology to reduce ship check labor costs. For cold spray, potential use cases were identified in the areas of structural plate corrosion repair, plate cracking, machined surfaces, and metallic component failure. There are still challenges to implementation with regards to repair process approval that remain. The path to qualify a new repair process was identified as the UIPI 6320-901 developed by PSNY.
Implementation
The primary purpose of this Special Project was to explore the feasibility of transitioning technologies developed in a public shipyard environment into a private shipyard environment.
*Prepared under ONR Contract N00014-14-D-0377 as part of the Navy ManTech Program.
*DISTRIBUTION STATEMENT A. Approved for public release: distribution unlimited. DCN# 43-9329-22
