alcoa sname-asne joint sdc mtg

7/31/2019 Alcoa Sname-Asne Joint Sdc Mtg

1/23

Alc oa Col laborat ive Design and

Development

Answering the Navys Call for New Lightweight Materialsand Structures to Optimize Naval Vessel Cost, Weight &

Performance

Nate Beavers SNAME-ASNE Joint SDC Meeting (June 25, 2008)Alcoa Technical Center724-337-4189


2/23

2

Present at ion Overv iew

Aluminum is a significant enabler of lightweight ship designssuch as LCS, JMAC, and JHSV, as well as, other ship

applications where weight reduction is important. Alcoa has significant resources and expertise for developing

optimized aluminum structures - weight, cost andperformance.

It is in Alcoas interest that the Navy and shipbuilders aresuccessful with current round of Al based ships.

Achieving next-generation breakthroughs in aluminum shipstructures, materials, coatings and manufacturingtechnologies requires collaboration and pull from the Navyand shipbuilders.


3/23

3

Sheet

Ingot

Smelting

Alumina

Mining

CastingsExtrusion Forgings FastenersAl, SA, Ti

Founded in 1888.40 countries; 450 locations.130,000 employees.$30B revenue in 2006.

Innovation LeaderMost Vertically Integrated Al Co. in the World.Environmental Sustainability Leader. Automotive

Aerospace

CommercialVehicles

Buildings

Defense

Plate


4/23

4

Over 100 Years of Tec hnic al

Innovat ion

UnparalleledLightweight Metallics

Technology

Metallics database unrivaled by any firm anywhere in theworld, the product of more than 100 years of research andengineering expertise

More than 60 years of experience in developing alloysand products for defense applications

Structural Design

Competencies

Critical design tools and competencies recognized inmultiple industries, including automotive, aerospace and

defense Design capabilities not limited to a single material or

product, but covering a range of solutions, includingthose that call for integration of aluminum with othermaterials

Fabrication andAssembly Capabilities

Strong manufacturing pedigree, chiefly born of its workmanufacturing integrated structures for the automotiveindustry

Extensive experience in producing prototypes ranging

from full assemblies to individuals parts Manufacturing and assembly issues viewed as critical

elements in the design process


5/23

5

Alc oa Sc ienc e & Techno logy

7 Research & Development Locations:

Alcoa Technical Center, PA, USA

Alicante, Spain (fabrication)

Carson, CA, USA (fastening systems)

Crawfordsville, IN, USA (closures)

Kwinana, Australia (refining)

Richmond, VA, USA (packaging)

Whitehall, MI, USA (castings)

3 External Technology Offices:

Beijing, China

Moscow, Russia

New Delhi, India

Alcoa Technical Center (ATC)

Worlds largest light metals research

facility

~600 scientists, engineers,

technicians & support personnel

Full range of lab capabilities

Bench-scale to full production-scale

equipment & facilities

Research, Development and Applied

Engineering across all products,

markets and processes


6/23

6

ATC Core Capabi l i t ies

Basic Science & MetallurgyBasic Science & Metallurgy

Alloy & temper development

Mechanical characterization

Deformation process design

Numerical simulations(material & process)

Metallurgical & engineeringstds.

Microstructurecharacterization

Constitutive equation dev.

Thermal process design

Subscale experimentalsimulation

Analytical Chemistry

Environmental Science Surface Science

Product ManufacturingProduct Manufacturing Metal shaping / forming

Machining / Metal removal

Joining & assembly

Rapid prototyping & tooling

Engineered Surfaces &Finishes

Manufacturing Systems /Manufacturing Systems /TechnologyTechnology

Control systems

Measurement systems

Manufacturing systemsanalysis

Statistical methods

Product Design / DevelopmentProduct Design / Development

Product design for:

Performance

Manufacturing

Cost

Computer-aided-engineering /design (CAE/CAD)

Design systems / methods /guidelines development

Material mechanics /characterization

Validation testing

Metal ProcessingMetal Processing Melting/recycling

Metal treatment

Ingot casting

Continuous casting

Process analysis

Solidification

Particulate processing


7/23


8/238


9/239

St ruc t ura l Design Capabi l i t ies

Alcoas design technologies have been successfully leveragedacross multiple commercial and defense market segments

Rail cars Transportation systems such as bulk trailers and intermodal

containers

Cars and trucks

Commercial aerospace Defense aerospace and land systems

Design is driven by customer performance requirements andstandards

Alcoa has found that its design competencies and toolkits are fullytransferable to other market segments once we learn a customersperformance requirements and standards

Alcoa is not as deeply immersed in maritime design requirements

and needs guidance on the communitys performance standards


10/2310

Col laborat ive Developm ent

Structural Design & Technology development is driven by customer andmarket requirements and is filtered through three critical concept areas.

OptimizedSolution

OptimizedOptimized

SolutionSolution

ManufacturingLimits2

Understandingpotential barrierspresented bymanufacturability

Material ScienceObjectives3

Understanding theunderpinning scienceto bridge ideal &achievable goals

Design Options1

Understanding how theproduct works tooptimize new featuresets

Customer Needs

Performance Drivers

Market Requirements

Mission Requirements

Customer NeedsCustomer Needs

Performance DriversPerformance Drivers

Market RequirementsMarket Requirements

Mission RequirementsMission Requirements


11/2311

Ground Syst em s Col laborat ion

Lockheed Martin JLTV

Lockheed Martin Announces Alcoa as aprincipal team member to compete for itsJoint Light Tactical Vehicle (JLTV)program.

Alcoa will supply materials knowledge,design services and aluminum

components that will give the vehicle itsstructural strength at reduced weight.

Blast and Shock Competencies

Alcoa is providing aluminum for up-armoring kits used to upgrade Humveesand heavy trucks that are being targetedby insurgents in Iraq and Afghanistan.


12/2312

Ground Syst em s Col laborat ion

Additional Areas

Gun Mount StructureLower Mission ModuleStructure Top Structure(32% weight savingsover Al baseline)

B-MODULE 760 lbs (51%) weight

savings vs. Al baseline

Prototype deliveredSep2006

TUBE SLEEVE & FLANGEFocus on manufacturability

Prototype delivered Aug2006

SADDLESTRUCTURE

75 lbs (12%)weight savings vs. Albaseline

Prototypedelivered Apr2006

FCS NLOS-C


13/23

Air Syst em s Col labora t ion

Three Point Bend Test

Bonded EA9360

Loaded to Failure

0

500

1000

1500

2000

2500

3000

0.000 0.100 0.200 0.300 0.400 0.500 0.600 0.700 0.800 0.900 1.000

Displacement, inches

Loa

d,

lb.

Limit Load

Ultimate Load .

Visible Upper Surface

Buckling

Test Development

Development

Product and

Manufacturing

Knowledge

ComponentDesign

CAD/FEA

Corrosion Testingand Expertise

Nose Landing Gear Door

Redesign resulting in lower

cost and improved fit up

F-22


14/2314

Air Syst em s Col laborat ion

JSF Design Concepts

F-35

Alcoa Solutions Flying Today -

Forged BulkheadsReplaces multi-piece design

10 - 15% wt saved

Improved buy-to-fly 50% current design


15/2315

7085 Wing spar produc ed atCleveland Plant for A380 p lane

(Largest d ie forg ing in the w or ld)

Location of 7085 die forgings on

the A380 wing

Inner Rear Spar

Gear rib/Sidestay attached

Inner Front Spar 1

Inner Centre Spar 1

Inner Rear Spar

Gear rib/Sidestay attached

Inner Front Spar 1

Inner Centre Spar 1

Alc oa A l loy, Proc ess ing & Fabr ic at ingTec hnolog ies Enable Large Aerospac eSt ruc tures


16/2316

Definition, coordination and execution

of internal and external conceptvalidation test programs (Large PanelTest Programs at Vought and Purdue)

Analys is, Test ing, Val idat ion and

Cer t i f i ca t ion


17/2317

17

Compr

ession

Optimi

zatio

nTo

olAspan-F

Fus

elag

eTo

olWingT

ool

Aspan-FP

FlatPanel

Tool

Aspan-COAspan-W

Alc oa Trade St udy Tools


18/2318

Model OutputK vs. a

Solution Page

Stress Output Deformation Output

ASPAN-W Wing Tool (c on t .)


19/2319

Alcoa is unique: Aluminum competency bred design toolsthat bred design capability that bred ACDA (DFM/DFA)

Partners:Lockheed MartinGeneral DynamicsBAE SystemsOshkosh Truck CompanyAM General

Al and Ti Products and ProcessExpertise

Design Tools and Models

StructuralDesign

CapabilitiesACDA andDFA/DFM

Partners:Lockheed MartinBoeingNorthrop Grumman

Increa

sedva

lueto

our

custom

ersis

timede

pend

ent


20/2320

Foc us for Navy Shipbui ld ing

3 MarineCoatings

4 JoiningTechnology

2 AlloyDevelopment

Alcoa is a leader in

aluminum alloyresearch anddevelopment and hasled in custombreakthroughs inclose cooperationwith industry partners

e las to - p las ti c

boundary

1 StructuralDesign

Alcoa is a proven

industry partner inproviding designsolutions foraluminum structuresand draws on awealth of propriety

tools and models

Alcoas coatingsexpertise promises toaddress critical fireresistance, frictionand non-skid issuesand can be deliveredas a systems solution

to the Navy

Alcoas advances innext-generationjoining technologyhas made it anindustry leader inFriction Stir Weldingand related processtool development


21/2321

Alcoa Collaborative Development Approach (ACDA IPTs)- Collaborative IPT Teams (OEM, Alcoa, Military) -

Phase I -Identify and Select Candidate Assemblies/Components

Phase II -Develop and Evaluate Conceptual Designs

Phase III -Finalize Conceptual Designs and AnalysesPhase IV -Develop and Evaluate Prototypes

Phase V -Implement Designs in Production

4thgate

3rdgate

2ndgate

1stgate

PartID

ConceptDesign

Proto-typing

ProductionFinal

Design

I II III IV V

Opportunityidentification

Gather geometry,packaging, load reqs

Develop conceptredesign options

Prelim. evaluation of

conceptual redesigns

Down-select concepts forfurther development

Ex. Activities: Finalize part redesigns

detailed CAD andanalysis

Evaluate advanceddesign concepts

Finalize total costs andplans for prototyping

Develop prototype partfabrication and test plans

Produce prototype parts

Test prototypes andapprove for production

Col laborat ion Approac h


22/2322

Current Ac t iv i t ies

Aluminum Lightweight Ship Structures Contract with Carderock LCS/High-Speed Vessel Structural Design:

LM LCS IPT GD LCS IPT

Austal JHSV IPT

Bollinger JHSV IPT

Materials development with Carderock New Alloy Development

Materials development workshop at Alcoa ATC

Engaging NSRP Panels

Trying to get Alcoa ManTech Divisions Involved

CG Superstructure Repair Assistance

Participating with ASNE and SNAME Activities

Other Ideas???


23/23

Alc oa Navy Program A Plan for Suc c ess

CUSTOMER VALUECUSTOMER VALUE

INDUSTRY APPLIED R&D EFFORTS(Broad Technology Diffusion)

-Lightweight Structural Design -Materials Development-Coatings Development -Joining Technologies

IPT DESIGN EFFORTS(Shipbuilder Discreet)

Innovative StructuresCollaborative DevelopmentPhased ApproachConcept Validation &Prototyping

Optimized Cost, Weight& Performance

New Shipyard Capability - Shrink Technology Gap Meet Navys Cost, Weight & Performance TargetsImproved Global Competitiveness Optimized Structure New Design Capability - Decreased Risk

Lower Life-Cycle Costs - New Production Technology - Part Reduction Lower Labor Costs

Shortened Production Schedule - More Unit Profit Differentiated ProductsNew Advanced Materials - Supply Chain Management

NAVY

R&DOrgs

ShipBuilders

OptimizedAl Ship

Structure

alcoa sname-asne joint sdc mtg

Documents