Expanded Adhesive
Outfitting Applications
June 16, 2015
Ship Design and Material Technology
Panel Meeting
Presentation Outline
• Status of Previous NSRP Adhesive Outfitting Efforts
• Update: Expanded Adhesive Outfitting Applications
– Deliverables From Last Quarter
• Draft Environmental and Survivability Test Plans
• Optimized Bonding Report & Procedure
– Activities for This Quarter
• Task 5: Finalize Guidelines for Selecting Adhesive Bonding Applications
• Task 6: Develop Detailed Test Procedures for Phase II Tests
• Plans for Next Quarter
• Summary & Closing
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Ingalls Shipbuilding
• Building four classes of ships simultaneously—
nine ships now in production
• Won a contract in June 2013 to build 5 additional
Arleigh Burke-class destroyers
• Builder of record for LPD and LHA classes of
amphibious assault ships
• Builder of largest multi-mission National Security
Cutter for the U.S. Coast Guard
DDG 51 Surface Combatants LPD 17 Class Amphibious Transport
USCG National Security Cutter
LHA 6 Amphibious Assault Ship
Previous NSRP Adhesive Outfitting Projects
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NSRP Panel Projects: Cost Reduction Measures for Local Cable Hanger Installations (SCRA 2012-439)
Cost Reduction Measures for Late Stage Outfitting (SCRA 2012-467)
Status Update: Adhesive Outfitting Approved on LPD Class Ships The LPD Contract has been modified to reference adhesive bonding in the relevant Specification Sections. Applies to: Compartments that are “signed off”, completed, or adjoining spaces, or adjacent to completed tanks
Items: Local cable runs and small boxes Deck berthing and furniture foundations
Bulkhead foundations
Limits: Repair, replacement, or relocation only Approved substrate only Approved Adhesive only Requires separate bonding / grounding Height restrictions Wire way hanger rules Requires NAVSEA approved bonding procedure
This approval is a starting point which leaves plenty of room for expansion with experience and better data.
Expanded Adhesive Outfitting Applications
Objective:
To expand applications for adhesive outfitting beyond specifically tested
and approved items by developing allowable load limits and design rules
for adhesively bonded studs
Technical Approach:
– Determine failure loads through shock and vibration tests
– Qualify adhesives through environmental tests
– Follow NAVSEA adhesive guidelines
– Establish design rules and identify any changes to ship specifications
required for implementation
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Team Members
• Ingalls Shipbuilding – Project Lead
– Sean Murphy, Jarrod Gilmore, Mark Losset, John Walks, Ronnie Romero, D G
McMillion
• Bollinger Shipyards
– Dennis Fanguy, Barry Matherne
• National Technical Systems
– Mike Poslusny, Tucker Thompson, Conner Smith
• SCRA
– Mary Saady, Project Manager
• NASSCO
– Dan Sfiligoi, Project Technical Representative
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Team Member Roles
Ingalls Bollinger NTS
Project Initiation Lead Support Support
Develop Requirements Matrix Lead Support Support
Develop Environmental and Survivability Test Plans Lead Support Support
Optimize the Adhesive Bonding Process Lead Support Support
Finalize Guidelines for Selecting Adhesive Bonding Applications Lead Support Support
Develop Detailed Test Procedures for Phase II Tests Lead Support Support
Execution of NAVSEA Approved Testing and Development of Implementation Requirements
Lead Support Support
Prepare Test Articles and Conduct Environmental Tests Co-Lead Support Co-Lead
Conduct Survivability Tests Support Support Lead
Develop Recommended Changes for Mounting Applications and Specification Requirements
Lead Support Support
Update Implementation Plan for use of Adhesive Design Rules in Outfitting Applications
Lead Support Support
Project Management Lead Support Support
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Project Work Breakdown Structure (WBS)
Phase I: Development of Technical Requirements for Expanded
Adhesive Outfitting Applications
Task 1…..Project Initiation
Task 2…..Develop Requirements Matrix
Task 3…..Develop Environmental and Survivability Test Plans
Task 4…..Optimize the Adhesive Bonding Process
Task 5…..Finalize Guidelines for Selecting Adhesive Bonding Applications
Task 6…..Develop Detailed Test Procedures for Phase II Tests
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Project Work Breakdown Structure (WBS)
Phase II: Execution of NAVSEA Approved Testing and
Development of Implementation Requirements
Task 7.….Prepare Test Articles and Conduct Environmental Tests
Task 8…..Conduct Survivability Tests
Task 9…..Develop Recommended Changes for Mounting Applications and
Specification Requirements
Task 10….Update Implementation Plan for use of Adhesive Design Rules in
Outfitting Applications
Task 11….Project Management
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Milestone Schedule – Phase I
Milestone Title Due Date
1 Project Management Plan 9/18/2014
2 Quarterly Report 9/20/2014
3 Kickoff Meeting Minutes 9/30/2014
4 Requirements Matrix Report 11/25/2014
5 Quarterly Report 12/18/2014
6 Quarterly Technical Review Minutes 12/18/2014
7 Quarterly Report 3/20/2015
8 Quarterly Technical Review Minutes 3/30/2015
9 Draft Environmental and Survivability Test Plans 3/30/2015
10 Optimized Bonding Process Report 3/30/2015
11 Quarterly Report 6/20/2015
12 Quarterly Technical Review Minutes 6/30/2015
13 Final Environmental and Survivability Test Plans & Procedures 6/30/2015
14 Guidelines for Adhesive Bonding Applications 6/30/2015
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Milestone Schedule – Phase II
Milestone Title Due Date
15 Phase II Kickoff Meeting Minutes 7/30/2015
16 Quarterly Report 9/20/2015
17 Quarterly Technical Review Minutes 9/30/2015
18 Quarterly Report 12/18/2015
19 Quarterly Technical Review Minutes 12/18/2015
20 Survivability Test Report 1/30/2016
21 Quarterly Report 3/20/2016
22 Quarterly Technical Review Minutes 3/30/2016
23 Environmental Test Report 3/30/2016
24 Updated Implementation Plan 4/30/2016
25 Final Project Report 5/20/2016
26 Final Technical Review Minutes 5/30/2016
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Activities this Quarter
Task 5 - Finalize Guidelines for Selecting Adhesive Bonding Applications
Task 6 - Develop Detailed Test Procedures for Phase II Tests
Request Approval of Phase II Funding
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Deliverables from Last Quarter
• Draft Environmental and Survivability Test Plans
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Environmental Test Plan
The test plan is designed to measure bond performance under a variety of
conditions outlined by NAVSEA. The main parameters are:
• Test Plates - Steel, Aluminum, Corrosion Resistant Steel (CRES) Honeycomb
• Bond Strength - Tensile and Shear
• Adhesives - Plexus AO420 and Click Bond CB200
• Attachments - Studs, Click Bond CB3200
• Conditions - Baseline, Corrosion / Aging, Elevated Temperature
• Variability - Lot to lot based on 3 lots
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Environmental Test Plans
• Test Plates – 5 Replicates per Plate
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Steel, Aluminum, Corrosion Resistant Steel (CRES) Honeycomb
Environmental Test Plans
• Bond Performance – Tensile and Shear
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Modified
Tensile
Modified
Offset Shear
Environmental Test Plans
• Environmental conditions:
– Baseline: Room Temperature Dry (simulates interior, conditioned spaces)
– Corrosion / Aging: Extended exposure in salt fog and elevated temperature
– Fluid Immersion: Extended exposure at elevated temperature (water, cleaning fluid,
lubricating oil)
– Elevated Temperatures:– Adhesive upper limit and elevated temperature corresponding to
an N-30 class boundary backside thermal rise)
– Curing Times: Curing curve at lower and upper application temperature limits
• Specific procedures / methods for fabricating test plates, bonding studs, and
performing are included in the plan or appendices.
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Survivability Test Plan
Overall Shock Test Series Objective
• The main objective of all the shock testing is to determine the shock
adequacy of various adhesive mounted stud configurations. This
objective can be broken into 2 main categories:
– Test various configurations to failure to determine the typical failure modes of the
adhesively mounted studs during shock.
– Test various configurations per the standards of MIL-S-901D for shock approval
• In general, the test series are developed to mitigate the risks of the
numerous variables that are involved in stud mounted equipment.
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Survivability Test Plan
LWSM Test Description
• The LWSM test series will be performed for adhesive mounted stud configurations consisting of one and two studs up to the weight limits of the shock machine.
• Series A will test the test specimens to failure to determine the weight capacity and failure mode. Multiple specimens will be tested to ensure repeatability and reduce the affects of any anomalies in the testing or fabrication of the specimens.
• The stud will be adhesively mounted and tested with a baseline weight. After the initial three blows in one direction, the weight will be increased and the third blow will be repeated. The weight will continue to be increased until a failure occurs.
• This process will be done in both the top and back directions. These failures will help Shock Engineering determine the failure mode of each adhesively mounted stud.
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Survivability Test Plan
LWSM Test Description
• This figure is an example of the
dummy weight fixture that will be used
on the single stud test specimens. A
similar approach will be used on the
two stud configurations. Test
specimen studs will be attached using
standard manufacturing guidelines.
The full details of the adhesive
manufactured guidelines will be
included in the detailed Series A and
Series B Test Procedures.
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Single Adhesive Mounted Stud Test Dummy Weight
Survivability
• Shock Test Plan and LWSM
Test by Ingalls
• Shock Test requirements
defined by Mil-S-901D
• Test Approach:
– Ranging Tests (single panel)
– Certification Tests (duplicate
panels)
– Repeat with multiple
substrates
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LWSM at Ingalls
Survivability
• Vibration Test Plan by
Ingalls and NTS
• Vibration Tests at NTS
Facility
• Test requirements defined
by Mil-S-167-1
• Test Approach:
– Cut Test Articles from Shock
Test Plates
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Vibration Table at NTS
Photo Courtesy of NTS
Deliverables from Last Quarter
• Adhesive Bonding Optimization Report & Bonding Procedure
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Example Click Bond Installation Procedure
Instructions Courtesy of Click Bond
Adhesive Bonding Process Optimization Report
This study and report was proposed for the following reasons:
– Certain bonding tests have produced variable results possibly due to differences
in the procedures used.
– Better guidance is needed to select the proper surface preparation method for
individual substrates.
– Better documentation is needed for bonding materials and process steps
– Lessons learned from previous installations shipyard experience needs to be
captured and communicated.
– NAVSEA requested that a shipyard document the procedure in a controlled
document.
This report will build on previous work to document the knowledge and lessons
learned from previous programs. The objective is to produce a comprehensive
Adhesive Stud Bonding Procedure.
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Adhesive Bond Process Optimization Report
• The discussion section will cover each step in the bonding process flow from
beginning to end as shown below. Materials and operations will be discussed
with respect to their suitability for shipboard installation and potential
alternatives.
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Step 1. Assemble Materials Step 2. Verify Conditions Step 3. Solvent Wipe Stud Base Step 4. Solvent Clean and Abrade SubstrateStep 5. Prepare AdhesiveStep 6. Apply Adhesive and Install Stud
Adhesive Bonding Process Flow
Highlights from Optimization Study
Adhesives
• Potential issues with these adhesives are that they are flammable in the
uncured state, they have a strong odor, they have very short working time in
hot conditions, and they have limited shelf life unless stored under
refrigeration. The project team discussed these topics and concluded they
were not a major issue for current shipboard installations.
• While newer methacrylate adhesives have been developed to address these
potential issues, the team determined that there was no reason to pursue
them until a specification for qualifying the existing adhesives was developed.
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Highlights from Optimization Study
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Abrasives
• Abrasives are used to prepare the surface for adhesive bonding. The main
objective in this report is to provide improved guidance on the types of
abrasives and where they are used. This incorporates lessons learned from
experience with test programs and training information provided by Click
Bond. The section on Cleaning and Abrading will provide additional guidance
on how the abraded surface should appear.
Rigid A24R WheelAl. Oxide Hand
Sanding PadDiamond Hand
Sanding Pad36 Grit Fibre Disc
Abrasive Materials Used for Surface Preparation
Highlights from Optimization Study
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Non-Flammable Solvents
• Approved cleaning solvents are flammable and require special handling.
Shock tests were conducted to compare the performance of two non-
flammable cleaning solvents. The chart below shows that they did not
consistently perform as well. They will not be carried forward into the full
environmental and survivability test programs.
Light Weight Shock Test Showing Score Based on Load at Failure
Highlights from Optimization Study
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Secondary Surface Preparation
• Variation in bond strength is most commonly due to inadequate surface
preparation. The approved procedure language for painted steel specifies:
– Abrade with 36 grit fiber disc
– “PAINTED STEEL SUBSTRATE shall be prepared to Society for Protective Coatings
(SSPC) surface preparation Standard SP-11. This is a visual standard requiring a minimum
1 mil. surface profile.”
Good - Rough Bad - Polished
Task 5 - Finalize Guidelines for Selecting
Adhesive Bonding Applications
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The project seeks to document and consolidate the various
guidelines that have been proposed for the use of adhesive
bonding.
• NAVSEA has issued reference documents which provide a
baseline set of guidelines.
• NAVSEA provided a template for adhesive use in conjunction
with the project Requirement Matrix Discussions
• NAVSEA directed certain restrictions in the LPD contract
modification.
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NAVSEA Source documents (restricted distribution):
• Use of Adhesively Mounted Studs in Naval Applications (Carderock,
2011)
• Fire Performance Requirements for Adhesively Bonded Studs Used to
Mount Furniture Items to Ship Boundaries (NSWCCD-61-TM–2006-19)
Task 5 - Finalize Guidelines for Selecting
Adhesive Bonding Applications
The goal is to negotiate a set of guidelines with no distribution restrictions and get NAVSEA signoff
Task 6 - Develop Detailed Test Procedures
for Phase II Tests
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Development of the detailed test procedures required to
execute the Environmental and Survivability test plans are
underway and expected to be complete by June 30, 2015.
The Adhesive Bonding Procedure, which will be used to
prepare test articles is complete and has been approved by
NAVSEA.
Request Approval of Phase II Funding
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The remaining Phase I deliverables are:
• Adhesive Bonding Guidelines
• Detailed Test Plans and Procedures
Upon submission of these reports (by June 30, 2015), the
project team will request approve of Phase II funding.
Phase II tasks include preparation of test articles, conducting
tests, analyzing results, and preparing recommendations for
implementation.
Plans for Next Quarter
• Kick-off Phase II
• Task 7 - Prepare Test Articles and Conduct Environmental Tests
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Questions
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