(LCS-1), used a stem cut from a steel plate, which required a signifi cant amount of labor to shape properly. T is caused many schedule delays and increased fabrication cost due to rework and weld inspection. Following this expe- rience, Lockheed Martin and the ship- yard, Marinette Marine Corp., sought an
alternative stem design to reduce fi t-up labor and improve accessibility for weld- ing and inspection. According to Akans, the new stem design was considerably more complex than the legacy design. T e V-shaped confi guration provided better access for the welder to join the stem to the hull plates.
THINK ABOUT
Sustainable Technology - Engineering Solutions for the Future
A team including the Navy Met-
alworking Center; Lockheed Martin; Marinette Marine Corp.; the Ameri- can Bureau of Shipping; Gibbs & Cox; Bollinger Shipyards Inc.; the Navy LCS program offi ce; Naval Surface Warfare Center, Carderock Division; and Newport News Industrial Prod- ucts worked to develop an optimized manufacturing solution involving a long cast stem that would ultimately meet the shipyards’ fi t-up and acces- sibility needs, the casting suppliers’ manufacturability concerns and the ABS’s performance requirements. To ease casting construction, the
cast stem was split into multiple cast- able pieces to reduce molding material requirements. T is allowed the ship- yard to adjust the cast stem fi t-up to structural components and facilitated incorporation into the current modular build plan for LCS. Marinette Marine Corp. procured
the cast stem from St. Louis-based Schoellhorn-Albrecht for installa- tion on the bow section of the second Freedom-variant LCS, the USS Ft. Worth (LCS-3). If one were to compare just the
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52 | MODERN CASTING August 2014 ONLINE RESOURCE
Take a look at more castings used in marine applications by viewing the Aquatic Castings gallery at
www.moderncasting.com
cast stem to the fabricated stem bar it replaced, the cast stem would cost more. But the added value of substan- tially reducing installation costs com- pared to the baseline method makes up for the diff erence. Additionally, the improved design allows for easier connection with the hull plates and reduced production time for the bow. “T e factors that go into a typical Business Case Analysis [for converting to casting] are pretty standard—the costs to produce and qualify the new solution compared with the expected benefi ts (labor, scrap and rework reduction, schedule impact, etc.) are typically the main factors,” Akans said. Ultimately, the cast stem reduces
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