Robotic Arc DED Directed Energy Deposition Additive Manufacturing

Robotic Arc DED (Directed Energy Deposition) Additive Manufacturing (AM) for Shipbuilding Breaking Barriers to Accelerate Implementation of Large-scale AM Team: EWI | Austal | Navus | NSWCCD | ABS | Ingalls | NASSCO Problem Statement • Shipyards need digital data workflow processes, advanced training programs, workforce competencies, qualification pathways, and standardized equipment and services for robotic arc DED AM implementation. • Shipyards need capability to build large AM structures and/or add features to structures Solution/ Approach – Develop: • • High Skew Propeller • Example: 16 -ft. Ø, 27 -tons • Casting defects and repair are major issue • DED builds offer improved NAB strength and toughness properties • ≈ Lead time 35 -weeks (DED) vs. years (castings) • ROM of $836 k (DED) • Opportunities for further cost and lead time reduction Large-scale equipment and services Digital data workflow training DED procedure and build models DED procedure qualification builds Test-bed “Lights-out” Robotic DED Alternate DED processes Prototypes, benchmarking, and design data Project Benefits • COTS large-scale gantry systems • Advanced process development • Multi-process capability test beds • Cleaning, grinding, NDE • Thermal and dimensional control • Property control and optimization • Workforce and training • Beta test site for Basic and Advanced Power. Mill DED AM courses ] Project ROI Major cost savings identified as replacement for large casting structures: • Large NAB propellers and impellers • Pressure piping components • Large equipment foundations features www. turbosquid. com Courtesy of Austal