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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
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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.
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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
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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
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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
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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
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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
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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
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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.
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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
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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
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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
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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
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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
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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
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Model OutputK vs. a
Solution Page
Stress Output Deformation Output
ASPAN-W Wing Tool (c on t .)
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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
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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
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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
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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???
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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