1. Navy Metalworking Center A ManTech Center of Excellence Advanced Metalworking Solutions for naval systems that go in harm’s way Distribution Statement A: Approved for public release; distribution is unlimited. This material is submitted with the understanding that right of reproduction for governmental purposes is reserved for the Office of Naval Research, Arlington, Virginia 22203-1995. Automated Weld Facing Tools Modified to Perform Back Gouging Bruce D. Horn and Timothy G. Freidhoff NMC/CTC American Welding Society New Welding Technologies Conference June 15-16 2010, Ft. Lauderdale, FL

2. Outline Integrated Project Team Problem and Solution Implementation Results and Benefits Conclusions and Movie Questions Manual Hand Grinding (Photo courtesy of NGSB-GC) NMC Weld Shaver Concept Project Outcome, Commercially Available Tool by PushCorp, Inc.

3. Integrated Project Team Bath Iron Works (BIW): Technical contributor and end user General Dynamics Electric Boat (GDEB): Technical contributor Naval Surface Warfare Center - Carderock Division (NSWCCD): Navy technical advisor Navy Metalworking Center (NMC): Project management and technical lead Northrop Grumman Shipbuilding - Gulf Coast (NGSB-GC): Technical contributor and end user Office of Naval Research (ONR): Project funding and support PMS 500 DDG 1000 Program Office: Stakeholder PushCorp, Inc.: Industry partner

4. Problem Butt welding of hull and deck panels produces weld protrusion reinforcement that exceeds DDG 1000 fairness limits Hand grinding is currently the only solution to removing weld Hand grinding is detrimental to the workforce, resulting in frequent injuries and costly medical expenses Current weld removal process (Photo courtesy of BIW) Weld Reinforcement Weld reinforcement cross section example (i.e., not DDG 1000)

5. Problem Hand grinding is slow, further increasing production costs. There are ≈ 21,000ft of weld reinforcement to remove per hull Flat orientation ≈ 45% Vertical and horizontal orientation ≈ 25% each Overhead orientation ≈ 5% (Photos courtesy of BIW)

6. Solution Perform assessment at BIW, NGSB-GC and GDEB to understand problems Develop prototype tool requirements to address shipyard’s design requirements Weld width up to 2.25" and height up to 0.3125" 20 ft/hr weld removal rate versus 3 ft/hr (1" wide weld x 0.3125" high) Remove 80% of weld height without damaging adjacent panel Individual component weight approximately 75 lbs or less Straight and contoured panels (40“ minimum radius, concave and convex) Flat, vertical, horizontal and overhead orientations Tool compliance to plate surface for maximum weld removal.

7. Solution Develop concept utilizing a commercially available weld shaver Flat orientationHorizontal orientation Vertical orientation Force control Carriage Track Magnets Weld seam Safety strap Slotting cutter Weld shaver

8. Solution Validate the track weld shaver concept for shipyard application Shaver and track lab test set-up Lab test results Weld shaver in production

9. Solution Shaver 3.7 HP AC Servo 7075 Aluminum Flex Track 40” R Min Vertical Axis Slide 2” Horizontal Slide 2” Force Control 100 lbs 2 Axis Shaver Rotation Rare Earth Magnet 220 lbs 2 Axis Rotation Track Quick Connect Cam WSF Alpha Prototype Tool

10. Solution Contract PushCorp, Inc. to develop track weld shaver concept and commercialize technology (Photo courtesy of PushCorp, Inc.) TWS91 commercially available tool from PushCorp, Inc.

11. BIW Implementation Results 60 ft of hull butt weld removed at approximately 60 ft/hr Finished hull weld (No hand grinding of weld required) Photos courtesy of BIW 3 in. wide x 12 ft long weld (75% labor reduction)

12. BIW Implementation Results 15 ft of hull butt weld removed at approximately 125 ft/hr Overhead orientation (Photos courtesy of BIW) Ship lifting lug weld removal

13. NGSB-GC Implementation Results 60 ft of hull weld removed at approximately 240 ft/hr Finished hull weld 30 ft of weld removed at approximately 60 ft/hr Photos courtesy NGSB-GC

14. Track Weld Shaver Benefits For panel and lifting lug weld removal, the estimated cost reduction for DDG 1000 is $924,000/hull Safer for the workforce Removes up to 90% of the weld height at a rate up to 240 ft/hr Automatic removal of weld between 0.375 and 3 inches wide Better for the environment Also being used to remove weld from ship lifting lugs Applicable for any applications requiring weld removal The track weld shaver system can be used to perform multiple operations (shaving, back gouging, sanding, welding and burning) Back gouging and sanding operations identified as additional capabilities and having potential for implementation

15. Track Weld Shaver Benefits Track weld shaver technology has potential back gouging use Back gouging total estimated cost reduction for DDG 1000, LHA-6, LPD-17 and NSC is $2,626,000 Manual carbon arc back gouging Mechanical back gouge cross section HSLA-80 plate (Photos courtesy of NGSB-GC) Mechanical back gouging HSLA-100 with MIL-120S-1 (Sample courtesy of BIW) 55° “V” 84 ft/hr NGSB-GC 12mm “U” 57 ft/hr BIW

16. Track Weld Shaver Benefits Manual sanding (Photos courtesy of BIW) Belt sander added to track weld shaver to blend shaved weld Finished 3 inch wide weld using belt sander (Photo courtesy of NGSB-GC)

17. Conclusions Track weld shaver technology is safer + faster than current hand grinding process, which = cost reduction Weld shaving estimated cost savings = $2.77M Back gouging estimated cost savings = $2.63M Track weld shaver system is currently implemented at the shipyards to remove weld reinforcement Track weld shaver technology has the potential to be used for back gouging, sanding, welding, and burning Back gouging needs further refinement and being considered for implementation by shipyards Track weld shaver system is now commercially available from PushCorp, Inc.

18. Contact Information NameOrganizationTitlePhoneEmail John FosterBIW DDG1000 Hull Representative 207-442-3464john.foster@biw.com Steve DavisBIW Lean Process Engineer 207-442-1728stephen.davis@biw.com Robert Kirkwood NGSB-GC DDG1000 Hull Representative 228-935-1546robert.kirkwood@ngc.com Kevin Roossinck NGSB-GC Sr. Welding Engineer 228-935-5761kevin.roossinck@ngc.com Tim FreidhoffNMC/CTCProject Engineer814-269-2876freidhof@ctc.com Bruce HornNMC/CTCProject Manager814-269-2351hornb@ctc.com Gene FrankeNSWCCDTechnical Advisor301-227-5571gene.franke@navy.mil Rick Zebrowski PMS 500, Program Office Stakeholder301-227-4410richard.zebrowski@navy.mil Edwin Erlbacher PushCorp, Inc.President972-840-0208erl@pushcorp.com

19. Technology Transfer Movie