Composites Road to the Fleet - - A Collaborative Success Story

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1 Composites Road to the Fleet - - A Collaborative Success Story Dr. John P. Hackett Director - Advance Ship Design, Hydrodynamics, and Signatures Northrop Grumman Shipbuilding Gulf Coast

2 CV Dr. John P. Hackett Chief Scientist & Director of Advance Ship Design, Hydrodynamics, and Signatures Northrop Grumman Shipbuilding Gulf Coast 40 years Marine Experience 36 years with NGSB Newport News Ingalls Avondale Former Chairman School of Naval Architecture & Marine Engineering - University of New Orleans Fellow - Society of Naval Architects and Marine Engineers 1996 Outstanding Researcher for Litton Industries 24 technical papers on Hydrodynamics and Ship Design Holds 3 Design Patents Areas of expertise - Early Stage Ship Design and Hydrodynamics 2

3 NGSB-GC History Litton Ship Systems Ingalls Shipbuilding Avondale Industries Acquired by Litton Industries in 1999 Gulfport composites facility Northrop Grumman Ship Systems (NGSS) Northrop Grumman purchases Litton in 2001 Access to other composite engineering and manufacturing centers throughout Northrop Grumman Corporation (NGC) Multi-million dollar capital investment in Gulfport composite facility Northrop Grumman Shipbuilding (NGSB) NGSS and Northrop Grumman Newport News joined in

4 NGSB-GC Research and Development (R&D) Ingalls was traditionally a large ship, high throughput, Metal Shipyard Ordinary Steel Specialty Steels (High Strength, High Yield, Stainless) Aluminum CuNi Titanium R&D established in 1975 Lightweight Materials Orthotropic Steel Construction NAVTRUSS, NAVSTEEL Built up sections (Ultrasonic Fab) Corrosion Resistance 4

5 Composites Advantages Lightweight Corrosion Resistance Flatness and Smoothness Signature Reduction Fatigue Life NGSB-GC Strategic Decision to Pursue Composites Potential material of the future Getting Knowledgeable Literature Search Visit/Team with Navy DTRC Visit/Team with Marine Composite Fabricators 5 Composite Case Studies AEM/S System Mast DDG 1000 CVN 77 DDG 51

NGSB-GC Marine Composite Technologies Development 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 ¼

Commissioned: 1993-1999 Joint Modular Lighter System Composite High Speed Vessel ½ Scale Midship Section Mfr Demo DDG Composite Hangar Test Article Project ½

6 NGSB-GC Marine Composite Technologies Development ¼ Scale AEM/S System Full Scale AEM/S on USS RADFORD AEM/S System on LPD 17 Detail Design and Construction of Osprey Class Composite Minehunters (MHCs) Commissioned: Joint Modular Lighter System Composite High Speed Vessel ½ Scale Midship Section Mfr Demo DDG Composite Hangar Test Article Project ½ Scale DDG51 Mast Composite Door Program DDG91 Remote Mine Hunting System Encl. DDG 1000 Composite Deckhouse Integrated Topside Demo System (ITDS) DDG 1000 Composite Deckhouse EDM 6

Radford at Sea (1996) Originally planned for a 6-month test and evaluation; however, the ship s s

Radar Cross Section (RCS) Numerous Articles and Papers Written Valley of Death Fleet Implementation

`96 Stick Mast Baseline System Mast Transition Planned for LPD 22 Radford Success Parts of OPNAV

7 AEM/S System Mast Transition to U.S. Navy Fleet ¼-Scale AEM/S Mast (1993/1994) Research Program AEM/S Mast on USS Radford at Sea (1996) Originally planned for a 6-month test and evaluation; however, the ship s s Captain requested it remain installed for the life of the ship Significant Performance Improvement Low Radar Cross Section (RCS) Numerous Articles and Papers Written Valley of Death Fleet Implementation AEM/S Mast Being Installed on LPD 17 (1999) Avondale Awarded LPD 17 Design & Construction Dec. `96 Stick Mast Baseline AEM/S System Mast Transition Planned for LPD 22 Radford Success Parts of OPNAV wanted the technology advanced, while others wanted it killed PEO & PM work with warrant holders Implementation Advance to LPD 17 Avondale Directed to Implement - Aug. `98 7 AEM/S Mast on LPD 17 at Sea (1999)

8 Transition to DDG 1000 Hangar Module (1991) Composite Door (1997) MARITECH Deckhouse (1998) Sealift Deckhouse (1998) ITDS was the Largest, most Sophisticated IRAD project Successfully led to DDG 1000 Integrated Deckhouse Low Radar Cross Section (RCS) High-End composites used Lightweight Planar Arrays Very Large structure Integrated Topside Demonstration System (ITDS) with Embedded Antennas Infused in Composite Panels (1999) Advanced Electric Ship Demonstration Deckhouse (2004) Low Observable Multifunction Stack (2001) 8 DDG 1000 Engineering g Development Model (EDM) (2003) DDG 1000 Deckhouse (2008)

9 Transition to DDG 51 Hangar Module (1991) ½ Scale DDG 51 Mast (1991/1993) Low Observable Multifunction Stack (2001) Significant design, manufacturing, and testing gprograms conducted with applicability for the DDG 51 class No transition of Composite to the DDG 51 class has occurred to date Composite Door (1997) Sealift Deckhouse (1998) 9 MARITECH Deckhouse (1998) DDG 51 Remote Minehunting Enclosure (2000) DDG 51 Composite Helo Hangar (1999/2002) Why? Class is in serial production; therefore, no impact to production were allowed? Funding shortfalls? No Incentive for PM to introduce new technology Opportunity for future transition?

Technology Transition Roadmap Office of Chief of Naval

Tomorrow S&T/R&D Valley of Death Office of Naval

Fleet of Tomorrow Navy Laboratories Help Develop and

Technical Solution to Meet Requirements for Fleet of

Construction Pay for Fleet of Tomorrow Shipbuilders

10 Technology Transition Roadmap Office of Chief of Naval Operations (OPNAV) Set Requirements for Fleet of Tomorrow S&T/R&D Valley of Death Office of Naval Research (ONR) Develop and Mature Technology to Meet Fleet of Tomorrow Navy Laboratories Help Develop and Test New Technology Ship Design Community Select Technical Solution to Meet Requirements for Fleet of Tomorrow Acquisition Community Manage Ship Design and Construction Pay for Fleet of Tomorrow Shipbuilders Design and Build Fleet of Tomorrow 10 Office of Chief of Naval Operations (OPNAV) Fleet

11 Shipbuilder s Lessons Learned for Transitioning Technology Organization Staffing Technology Opportunity Culture Risk Need for a Champion Funding Source 11

12 Shipbuilder s Lessons Learned for Transitioning Technology R&D Organization NGSB-GC Dedicated R&D Group IRAD CRAD TPOC Manager R&D Director R&D Business Development Administrative Support Product Documentation R&D Technical Note TPOC Manager R&D Director R&D Contract Administrator Program Manager Administrative Support Product Documentation Contract specific Typically y monthly reports, Preliminary Report, Final Report. Reviews IPDRs & Final Review 12

13 Shipbuilder s Lessons Learned for Transitioning Technology Staffing Composite Specialists Composite Engineering established Three Engineering g Skills sets desired Ship Structural Engineering (steel/aluminum) Finite Element Analysis Marine Composite Engineering Not readily available in national Labor Pool Settle for two of three and Train Similar for marine composite Structural Designers Ship Structural Designer (steel/aluminum) Marine Composite Designer Manufacturing Craft Marine Composite Maintaining Critical Mass 13

14 Shipbuilder s Lessons Learned for Transitioning Technology Technology Opportunity for Introduction into Fleet Navy must Approve all technologies that make up the Ship System Advantage to Warfighter Cost Advantage Acquisition vs. Total Ownership Cost Close Collaboration with Navy Warrant Holders Insertion Road Map with off-ramps Best for ships still in Concept/Preliminary Design May need Engineering Development Models (EDMs) Not impact construction ONR/NAVSEA should hold routine reviews and Technology Conferences with potential: Warrant Holders Program Officers Navy Labs Shipyards 14

15 Shipbuilder s Lessons Learned for Transitioning Technology Culture Emotional Reaction Resistance to Change Fear of Unknown Occurs in All Organizations Shipbuilder NAVSEA Tech Codes PMS Overcome With: Facts Patience Warfighting Benefits Decision Process Resistant to Change 15

16 Shipbuilder s Lessons Learned for Transitioning Technology Risk Understand who the Warrant Holders are Honest assessment of Advantages and Disadvantages of technology Identification of Risk Risks may be real or perceived Risk Mitigation Plan Address concerns of all warrant holders Requires time and money Technical Papers Refereed Journals ASNE SNAME 16

17 Shipbuilder s Lessons Learned for Transitioning Technology Need for a Champion Three Revolutionary Technologies since WWII Nuclear Power Ballistic Missile Submarine, Weapon Systems & Missiles AEGIS Ships & Weapon System Led by: Admiral Rickover (33 years) Admiral Raborn (7 years) Admiral Meyers (13 years) Attributes of the above Leaders Vision Authority Money Longevity of Service 17 (continued)

18 Shipbuilder s Lessons Learned for Transitioning Technology Need for a Champion (continued) Champion needed in all pertinent organizations Shipbuilder OPNAV PEO PM Tech Code ONR Skills need by Champion Interpersonal skills Influence in their Organization Respected Technically and Business wise Team builder Perseverance Must continue to find/grow champions throughout the life of the program PM tour of duty greater than four years 18

19 Shipbuilder s Lessons Learned for Transitioning Technology Funding Sources for Composites IRAD IRAD / NSWC-CD CD CRADA NSWC-CD ONR Programs (PMS) MSC MARAD Congressional Earmarks (administered through other agencies) Funding source not always clear 19

20 Summary ONR successful in bringing Composites to the Fleet Northrop Grumman has invested in marine Composites since 1989 Facilities & tooling, Composite Engineering, i Training i Projects have ranged from small scale test articles to entire Ship Sections Many sources of funding have been utilized, covering the spectrum of IRAD, USN, and others. Several projects have transitioned Successfully to the fleet AEM/S System Mast ATD on U.S.S. Arthur W. Radford LPD 17 class Composite Deckhouse ITDS DDG 1000 Integrated Deckhouse Multiple mast projects contributed to the CVN 77 forward mast Unsuccessful in transitioning composite technology to DDG 51 Class Helo Hangar RMS Enclosure Masts, Stacks, etc? No clear Champion for composites 20

21 Conclusion Transition has been successful due largely to demonstrating the Warfighter benefit and overcoming risk and cultural barriers All ship design stakeholders must work in bridging the valley of death ONR, NAVSEA Tech Codes, PMSs, PEO, OPNAV, Shipbuilder Need to focus Process Need to incentivize PMs to adapt new technology ONR should restart the annual program day overview briefs Invite Navy labs, NAVSEA Tech Code, PMSs, & shipyards Shipbuilders can be helpful in developing and transitioning technologies NEED CHAMPION 21

22 Backup

23 Composites Research Timeline at NGSB-GC Project Name Funding Source U.S.S. Pelican (MHC 53) PMS 490 Miscellaneous Early Small Test Articles IRAD/CRADA/NSWC CD 1/2 Scale DDG 51 Mast IRAD/CRADA/NSWC CD [ONR(6.2)+DNA] Hangar Module IRAD/CRADA/NSWC CD / [ONR(6.2)+DNA] 1/4 Scale AEM/S System Mast ONR ATD Composite Platform NSWC CD [ONR(6.2)] Composite Hull Section NSWC CD [ONR(6.2)] Full Scale AEM/S System Mast ONR ATD Composite Door IRAD Composite RCS Test Fixtures IRAD/CRADA Sealift Deckhouse MSC Maritech Deckhouse MARAD LPD 17 Composite Mast PMS 317 IntegratedTopside Demonstration System (ITDS) IRAD DDG 51 Composite Helo Hangar ONR DDG 51 Remote Minehunting System (RMS) Enclosure PMS 400 Low Observable Multi function Stack ONR Joint Modular Lighterage System (JMLS) NSWC CD C CHSV ONR CVN 77 Mast PMS 378 AESD Deckhouse ONR ATD DDG 1000 Test Articles (RCS, Joints, Fire and Shock) PMS 500 DDG 1000 Deckhouse Engineering Development Model (EDM) PMS 500 DDG 1000 Integrated Deckhouse Start Fabrication PMS 500 Litton Buys Avondale 23 Northrop Grumman Buys Litton 16 June 2010

Composite Mast Transition to CVN 77 DDG 51

as a replacement for aluminum ½-Scale DDG 51 Mast

mast with Composite structure Form-fit-function

Sea (1996) 24 AEM/S Mast on LPD 17 at Sea (1999)

24 Composite Mast Transition to CVN 77 DDG 51 composite stick mast demonstrated t d Composites as a replacement for aluminum ½-Scale DDG 51 Mast (1991/1993) Replace upper portion on CVN steel mast with Composite structure Form-fit-function replacement for steel AEM/S Mast on USS Radford at Sea (1996) 24 AEM/S Mast on LPD 17 at Sea (1999) CVN 77 Mast Under Construction (2003) Mast Installed on CVN 77 (2003)

25 Transition to Future Composite Hulls? U.S. Navy Coastal Minehunter Composite Hull Section (1989) (1995) Does more R&D need to be conducted d to Mature the Technology in the customer s eyes? Hull length limitation tato of ~ 100m Joint Modular Lighterage System (2001) Joint Modular Lighterage System (2001) Cost Constraints? 25 Composite High Speed Vessel (2003) Composite High Speed Vessel (2003)

Composites Road to the Fleet A Collaborative Success Story

SPECIAL REPORT 306: NAVAL ENGINEERING IN THE 21ST CENTURY THE SCIENCE AND TECHNOLOGY FOUNDATION FOR FUTURE NAVAL FLEETS Composites Road to the Fleet A Collaborative Success Story John P. Hackett Northrop