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Huntington Ingalls IndustriesOverview of Ingalls Shipbuilding: Industrial Application of
Composite Technology
14-15 MARCH 2013
Huntington Ingalls Industries (HII)Corporate Highlights
• Annual revenues of approximately $6.6 billion, backlog of more than $16.3 billion.
• Employees: more than 37,000; largest private employer in Mississippi and Louisiana, and largest industrial employer in Virginia
• Key Locations:
– INGALLS SHIPBUILDING• Pascagoula, MS – DDGs, LHAs, LPDs, Cutters• Gulfport, MS - Composite R&D, Composite Components• New Orleans, LA - LPDs, TAKRs, TAOs• Virginia Beach, VA - Fleet Support (AMSEC)• San Diego, CA - Fleet Repair & Support (Continental Maritime)
– NEWPORT NEWS SHIPBUILDING• Newport News, VA – CVNs, SSNs, RCOHs
The Nation’s Leading Military Shipbuilder
Surface Combatants
Amphibs
National Security Cutters
Fleet Support & Other
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HII-Ingalls ShipbuildingLocations & Products
DDG 1000
DDG 51LPD
NSC
LHA
Gulfport
CMSD
Pascagoula
Avondale
AMSEC
• Annual Revenue: ~$3 billion• Employees: ~14,000 employees at
5 sites• Major Programs
– LHA– LPD 17– DDG 51– USCG National Security Cutter– DDG 1000 Deckhouse
Largest manufacturing employer in Mississippi and a major contributor to the economic growth of the state of Alabama 18
HII Ingalls Shipbuilding, Pascagoula
MS Spend 2010-2011Total - $219,865,138
4/2/2013
AdamsBolivarCarroll Clay Copiah DeSoto Forrest 242,557George Greene Hancock 12,267Harrison 12,350,107Hinds 510,011Jackson 198,283,970Jones 2,120,945Lafayette 33,895Lamar 48,050Lauderdale 2,709Lee 118,486Leflore 10,700Lincoln 2,179Lowndes Madison 3,017,867Marion 372,393Monroe Oktibbeha 97,308Panola Pearl River Perry Pike 22,375Pontotoc 87,761Quitman Rankin 635,922Smith Stone 1,384,444Tate Walthall Warren 3,063Winston 508,128
• 125 acre site
• 85 developed / 40 available
• Access to Gulf of Mexico
• Dredged depth – 12ft
• Height restriction – 95ft
• Location:
• 4 lane hwy to facility entrance
• 2.7 miles to Interstate 10
• 3.8 miles to Gulfport Intl. Airport
HII IngallsGulfport Composite Center of Excellence
Gulfport Center of ExcellenceCapability and Capacity
Capability• Composite materials provide innovative
solutions to mission system and structural design requirements extending capability beyond comparable metallic structures
• Unmatched capability to manufacture large scale marine composite structures; cored or non-cored with glass or carbon fiber cloth
• Successfully constructed world’s largest marine carbon fiber composite components for DDG 1000 Program
• Robust composite R&D capability for process and product technology advancement
Capacity• Flexible plant infrastructure able to support
multiple projects and project types
• Over 322,000 ft2 covered manufacturing space; 253,450 ft2 environmentally controlled
• Two flat panel molds capable of constructing single panels up to 8,000 ft2 each
• 7,500 ft2 of core construction tables
• All manufacturing bays equipped with bridge cranes – max lift capacity over 400 ton
A National Asset
Gulfport Center of ExcellencePeople and Processes
People• Only Department of Labor certified
Composite Apprentice Program in the United States
• All employees receive a minimum of three weeks training before entering the workforce
• Successfully hired, trained and assimilated over 600 employees into workforce between January 2009 and present
• Awarded OSHA Voluntary Protection Program (VPP) STAR certification for 2010 reflecting engaged workforce actively maintaining a safe workplace
Processes• VARTM, or Vacuum Assisted Resin
Transfer Molding
• Extensive ultrasonic non-destructive testing ability, including process development and qualification
• Quality checkpoints integrated into all work instructions
• Achieving near 4 sigma quality in carbon fiber flat panel and joint construction
• Process and procedural compliance verified at over 99% adherence
A National Asset
HII IngallsGulfport Composite Center of Excellence
Indexing LedgeIndexing Ledge•• Enable deckhouse Enable deckhouse and hangar and hangar deliverydelivery
WarehouseWarehouseEnvironmentally Environmentally controlledcontrolled30,000 sq30,000 sq--ftftSecured AreaSecured AreaOffices/Restrooms Offices/Restrooms
Bay 6 Assembly and Erection BayBay 6 Assembly and Erection Bay
Unit Assembly and Deckhouse Erection Unit Assembly and Deckhouse Erection 2 Unit Assembly Area2 Unit Assembly Area2 Deckhouse Erection Positions2 Deckhouse Erection Positions2 2 -- 225 Ton Bridge Cranes225 Ton Bridge CranesEnvironmentally ControlledEnvironmentally ControlledOffice/RestroomsOffice/RestroomsSmall Outfitting ShopSmall Outfitting Shop
LEGENDLPD Manufacturing
DDG ManufacturingUpgrades supporting DDG Program
Bay 2 TurnoverBay 2 TurnoverExpanded composite panel fabrication line Expanded composite panel fabrication line 120 Ton Turnover Crane120 Ton Turnover CranePanel turnover area for inspectionPanel turnover area for inspectionEnvironmentally ControlledEnvironmentally Controlled
Resin Storage and MixingResin Storage and MixingResin Storage Resin Storage Resin Mixing Resin Mixing QA Lab QA Lab
Bay 2 Bay 2 Bay 2 Extension Bay 2 Extension -- Assembly AreaAssembly Area157157’’ Building ExtensionBuilding ExtensionEnvironmentally ControlledEnvironmentally ControlledCrane CoverageCrane Coverage55--axis CNC Machining Centeraxis CNC Machining Center
Bay 2Bay 2Mold Tables Infusion AreaMold Tables Infusion Area2 2 -- 50 Ton Cranes50 Ton Cranes2 652 65’’x140x140’’ Mold TablesMold TablesEnvironmentally ControlledEnvironmentally Controlled
Bays 3 & 4Bays 3 & 4LPD Mast and R&D Infusion BaysLPD Mast and R&D Infusion Bays1 1 –– 40T & 140T & 1-- 50T Crane50T CraneEnvironmentally ControlledEnvironmentally Controlled
Bay 1Bay 1LPD Mast and R&D Assembly BayLPD Mast and R&D Assembly Bay2 2 –– 160 Ton Cranes160 Ton CranesEnvironmentally ControlledEnvironmentally ControlledCovered SlipCovered Slip
Bay 5 Core FabricationBay 5 Core FabricationCore Fabrication Core Fabrication 11-- 50 Ton Crane50 Ton CraneCore TablesCore TablesEnvironmentally ControlledEnvironmentally Controlled
Over $60M in Capital Improvements
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Leveraging Mississippi Assets
• University of Southern Mississippi– Economic Impact Assessment of Shipbuilding Plans– Market Analysis of Composite Opportunities– Composite Marketing Brochure Support
• MDA and MEDC– Multiple Introductions to Energy/Oil and Gas Opportunities
• Composite Blow Out Preventers, Hydrogen Storage Tanks, Wind Turbines, Digester Tanks etc.
• Mississippi Enterprise for Technology (Stennis Space Center)– Monthly Lunch and Learn
• Stennis Business Consortium– Quarterly industry meetings– Expo Events
Composite DeckhouseUSS Zumwalt
and joining it to a traditional shipbuilding processes
Making our own “steel”
Panel assembly Ship-shape unit Unit outfittingUnit integration
Max Launch Abort System (MLAS) Prototype Component Fabrication
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• Alternative launch abort system for Orion crew module supporting NASA’s Constellation Program
• Built to Aerospace design standards
– utilized complex shapes quality standards, and processes
• Used Marine materials and Labor for fabrication
– Labor rates significantly below Aerospace rates
• Adapted facility, workforce, and processes to meet design and manufacturing requirement
Image Source: NASA
(Fabricated at Ingalls)
(Fabricated at Ingalls)
(Fabricated at Ingalls)
VIDEO OF MLAS LAUNCH:http://www.nasa.gov/multimedia/nasatv/on_demand_video.html?param=http://anon.nasa-global.edgesuite.net/qt.nasa-global/ccvideos/larc/mlas-launch.mov&_id=undefined&_title=undefined&_tnimage=test.gif
Modifications Needed for Aerospace Fabrication
• Increase shop cleanliness – may require certification to ISO 14001 standards
• Upgrade and expand pre-preg capabilities– Autoclave, Fiber Placement equipment , Ovens, etc
• Align Engineering Aids and Manufacturing Execution System (MES) with aerospace requirements
• Personnel Training for required materials & processes
15 Image Source: NASA & Vistagy Software
Exploring Future Opportunities
History at Gulfport• (4) Composite Mine Hunters
• (75) Steel Barges (200ft ea)
• (1500) Assembly Units for Avondale
• Composites R&D
– Joint Modular Lightering System Barges
– ONR Composite High Speed Vessel Program
– DDG Topside Structures
– LHA Island Components
– Max Launch Abort System Demo (NASA)
– Aperstructures – Advance Antenna Integration
• CVN 77 Mast
• LPD Masts
• DDG 1000 Deckhouses
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Value Proposition• Ingalls Composite mechanic labor rates
lower than typical aerospace
• Ingalls has (aerospace & mechanical) engineers with aerospace experience
• Skilled craft workforce, capable of learning new processes
• Capability and capacity for parts ranging from small to very large
• Facility upgradable to meet Aerospace requirements
• Proximity to transportation options
Turbine Blades
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• Large, Complex Shapes
• Location accessible to Land-based wind farms
• Ideal location for offshore wind
• Growing market
• Subsidy dependent
• Potential for foreign Company partnership
Composites for Roadway Bridges
• Composite technology is mature, and worldwide use is growing
• Composite or hybrid-composite bridges are affordable and extend expected bridge life compared with traditional steel/concrete
• Manufacturing processes allow for modular, off-site production of components
– Reduces install time at bridge site– Lightweight panels and beams reduce demand
for heavy equipment required for fabricationKnickerbocker Bridge, Boothbay Harbor, Maine
Composite Bridge, Chicago
Offshore Supply Vessels & Small Boat Market
• Vessels include:– Tugboats– Offshore supply vessels– Support vessels– Crew boats– Drilling rigs
• Provider of Supplies and spare parts through support services
Other Applications with a Composite Advantage:Waterfront
Submarine CamelShip Separators
Trench CoverPipe Camel
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Ingalls Gulfport Approach
• Work with MDOT to assess need/demand for bridges within the state of Mississippi
• Team with MDA, University of Southern Mississippi, and compositebridge technology company (such as HC Bridge Co. or other TBD)
– Select three ideal locations w/in state– Each location to offer unique benefits/challenges for implementation– Develop design options for each location
• Work with MDOT and State of MS to acquire funding for selected bridges
• Fabricate and install composite bridge solutions at three MS locations