Robert Petersson Naval Architect M.Sc. Composite & Strength - PowerPoint PPT Presentation

Naval Composite Technology Transfer Transfer of Naval Technology to Commercial Shipbuilding Applications Robert Petersson Naval Architect M.Sc. Composite & Strength Naval Surface Ship / Hull Dept. KOCKUMS

Naval Composite Technology Transfer Introduction Transfer of Naval Technology to Commercial Shipbuilding Applications Naval Composite Technology Transfer Feasible Transfer of Naval Technology to Commercial Shipbuilding Applications

Naval Composite Technology Transfer Naval Composite Technology Transfer Introduction Transfer of Naval Technology to Commercial Shipbuilding Applications Transfer of Naval Technology to Commercial Shipbuilding Applications • Company background • The Naval Corvette Project • Advantages and disadvantages • Benefits from Naval Corvette Project • LCC perspective • Feasible applications

Naval Composite Technology Transfer Composite History Transfer of Naval Technology to Commercial Shipbuilding Applications 1963 1974 1980 1984 1987 1988 1990 1992 1995 40 Years Experience in 1998 Advanced Composite Ship Design and Manufacturing

Naval Composite Technology Transfer Naval Composite Technology Transfer Composite History Transfer of Naval Technology to Commercial Shipbuilding Applications Transfer of Naval Technology to Commercial Shipbuilding Applications The Visby Class Naval Corvette (2001) 40 Years Experience in Advanced Composite Ship Design and Manufacturing

Naval Composite Technology Transfer The Visby Corvette Transfer of Naval Technology to Commercial Shipbuilding Applications The world’s largest moving object built in CFRP sandwich: • Length 73 m • Breadth 10.4 m • Displacement 600 ton • Speed 40 knots Each ship consists of ~160 ton composite materials… Series of totally five (5) ships...

Naval Composite Technology Transfer Military Advantages Transfer of Naval Technology to Commercial Shipbuilding Applications Military advantages of CFRP sandwich: • Non-magnetic material (mines) • Extremely flat surfaces (radar) • High thermal insulation (IR) • High underwater shock resistance • High EMC protection

Naval Composite Technology Transfer General Advantages Transfer of Naval Technology to Commercial Shipbuilding Applications General advantages of CFRP sandwich: • Low structural weight, which gives (either): - Fuel savings - Higher payload - Increased service speed - Longer range • Non-corroding structure (low maintenance cost) • Built in thermal insulation (also rust proofing) • Built in acoustic insulation • Engineered materials for optimised design solutions • Composites less sensitive to fatigue

Naval Composite Technology Transfer Disadvantages Transfer of Naval Technology to Commercial Shipbuilding Applications Commercial disadvantages of composites in shipbuilding: • Higher acquisition costs • Combustible material (fire) • Lack of Class Rules (Lloyd´s, DNV, ABS) • Complicated QA/QC • Recycling Solutions from Naval Corvette Project…

Naval Composite Technology Transfer Solutions and Benefits Transfer of Naval Technology to Commercial Shipbuilding Applications Solutions and benefits from the Naval Corvette Project: • Structural fire integrity • Influence on Legislation and Class Rules • NDT methods suited for efficient QA on very large structures • Studies on disposal of composites

Naval Composite Technology Transfer Solutions and Benefits Transfer of Naval Technology to Commercial Shipbuilding Applications Additional benefits from the Naval Corvette Project: • Material test methods • Structural analysis methods (FEM) • Large-scale production of planar sandwich panels • Rational NC water jet tooling of sandwich panels • Assembling, housing and post-curing of very large structures

Naval Composite Technology Transfer Life Cycle Cost Transfer of Naval Technology to Commercial Shipbuilding Applications LCC comparison on High Speed Ferry Life Cycle Costs: • Acquisition costs • Operational costs • Disposal costs Three versions: Length 128 m Cars 250 • Steel / Aluminium Passengers 1000 • All Aluminium Lifetime 25 years • All CFRP Sandwich

Naval Composite Technology Transfer Life Cycle Cost Transfer of Naval Technology to Commercial Shipbuilding Applications LCC comparison on High Speed Ferry 450 400 350 300 Operation & 250 Maintenance M€ 200 Acquisition cost 150 100 50 0 Steel Aluminium Composite • 22 % lower LCC for composite • Up to 30 % savings in LCC possible

Naval Composite Technology Transfer LCC Break-Even Transfer of Naval Technology to Commercial Shipbuilding Applications LCC comparison on High Speed Ferry Steel Aluminium Composite 400 Composite vs Aluminium 350 B-E after 12 years (10 years of operation) 300 Composite vs Steel 250 B-E after 4 years M€ (2 years of operation) 200 150 100 50 0 0 5 10 15 20 25 30 Years

Naval Composite Technology Transfer Commercial Applications Transfer of Naval Technology to Commercial Shipbuilding Applications Superstructures in GRP sandwich?

Naval Composite Technology Transfer Commercial Applications Transfer of Naval Technology to Commercial Shipbuilding Applications Cargo (RoRo) decks of sandwich panels?

Naval Composite Technology Transfer Commercial Applications Transfer of Naval Technology to Commercial Shipbuilding Applications Cargo hatches of sandwich panels?

Naval Composite Technology Transfer Feasible Advantages Transfer of Naval Technology to Commercial Shipbuilding Applications Feasible advantages of CFRP (or GRP) sandwich for commercial shipbuilding applications: • Fuel savings • Lower maintenance costs • Increased hydrodynamic stability Superstructures Cargo decks Cargo hatches

Naval Composite Technology Transfer Superstructures Transfer of Naval Technology to Commercial Shipbuilding Applications Pure Car/Truck Carrier Length 200 m Deadweight 15 000 tons Height 50 m Capacity 6 000 cars

Naval Composite Technology Transfer Superstructures Transfer of Naval Technology to Commercial Shipbuilding Applications Composite Superstructure? • Steel superstructure weight ~ 600 tons • GRP sandwich weight ~ 300 tons • Lowered VCG Steel VCG Increased stability GRP VCG Increased payload!

Naval Composite Technology Transfer Summary Transfer of Naval Technology to Commercial Shipbuilding Applications To conclude: Steel Aluminium Composite 400 • Advanced composite materials 350 300 have advantages for commercial 250 M€ shipbuilding applications 200 150 100 • LCC analysis show break-even 50 0 in a few years 0 5 10 15 20 25 30 Years • Beneficial solutions from Naval Corvette project • Feasible transfer to commercial shipbuilding applications • Solutions for composite superstructures on steel ships "A strong Chain of Composite Design "A strong Chain of Composite Design and Manufacturing Know-how" and Manufacturing Know-how"

Naval Composite Technology Transfer The End Transfer of Naval Technology to Commercial Shipbuilding Applications Thank You !