Kul-24.

4130
Shipyard engineering

Lecture 3-2:
Hull production – Steel processing methods

Applied Mechanics
Marine Technology
Lecture in course contents
Production Introduction
planning

Shipbuilding process and

ship yard productivity

Outfitting

Design process
and materials
management

Hull production
Objectives, contents and literature
• Learning objective:
– Understand the main manufacturing methods used in block and hull production
– Know the equipment used in material handling and transporting

• Contents:
– Cutting methods
– Plate and stiffener bending
– Welding processes
– Material handling

• Literature
– Laivatekniikka. Räisänen toim., 2000
– Ship production, Storch et al., SNAME, 1995
Cutting methods
• The aim if parts cutting, but also the
beveling and groove manufacturing
• Thermal cutting processes
– Flame cutting
– Plasma arc cutting
– Laser beam cutting
• Thermal cutting machines
– Small flame cutting machines
– Parallel cutting machines
– NC controlled cutting machines
• Mechanical cutting methods and
machines
– Water jet cutting
– Press shears
– Disk shear
– Milling
Comparison of cutting methods
Measures for
comparison:
• Productivity
• Accuracy
• Distortion
• Plate thickness
• Groove
manufacturing
and beveling
• Cutting of
openings
• Environmental
impact
Forming methods

• Thermal forming
(line heating)
• Rolls
• Bending press
• Press
• Press brake
• Frame benders

• Flame straightening
• Roll-straightening
Forming methods

• Thermal forming
(line heating)
• Rolls
• Bending press
• Press
• Press brake
• Frame benders

• Flame straightening
• Roll-straightening
Forming methods

• Thermal forming
(line heating)
• Rolls
• Bending press Gap press
• Press
• Press brake
• Frame benders

• Flame straightening
• Roll-straightening
Press brake
Forming methods

• Thermal forming
(line heating)
• Rolls
• Bending press
• Press
• Press brake
• Frame benders

• Flame straightening
• Roll-straightening
Forming methods

• Thermal forming
(line heating)
• Rolls
• Bending press
• Press
• Press brake
• Frame benders

• Flame straightening
• Roll-straightening
Welding processes
Arc welding process
• MIG/MAG-metal arc welding
– Gas-shielded metal arc welding (GMAW)
– Metal inert gas welding (MIG)
– Metal active gas welding (MAG)
• Flux cored arc welding (FCAW)
• Electro gas welding (EGW ) Butt weld
• Submerged arc welding (SAW)
• Electro slag welding (ESW)
• Shielded metal arc welding (SMAW)
Other welding process
• Friction Stir welding
• Laser-hybrid welding Fillet weld
MIG/MAG and flux cored arc welding (FCAW)

• MIG/MAG
– The arc between the filler and parent metal
– Active or passive shielding gas
• Flux cored arc welding FCAW
– A hollow filler wire with flux
– The most important and common welding
method in ship building
– Suitable for various materials and all
welding positions
Electro gas welding EGW
• EGW is a development of electroslag
welding
– Welding in mold
– Single pass welding for thick plates
• Mainly used for
– Vertical seam in shell plates
– Tanker’s bulkheads
Submerged arc welding SAW
• The metal arc welding, where
the molten weld and arc zone
are protected by granular
composition
• Typically automatized
– Rail, tractor
• Mainly used for:
– Butt joint between plates
– Joint between web frame
and deck plate
– Web-flange joint in T-
beams
Electro slag welding ESW
• Fusion welding method, in which a current passes
through the slag layer
• Mainly used for:
– I-beam of tankers deck structure
Shielded metal arc welding SMAW
• Manual metal arc welding,
where the arc is between
the electrode and metals
to be joined
– The electrode coating
forms a protective gas
– FCAW replaced in the
1980s

• Currently used:
– Outside, in all-weathers
– Tanks far away from
power supply
Friction Stir Welding
• Rotating tool causes the
frictional heat that joins the
work pieces in the joint area
and the tracks are
interconnected
• In shipbuilding, friction stir
welding is used for the
manufacturing of aluminum
decks
– Joining of the extruded
profiles together resulting in
deck plate with stiffener
Laser-hybrid welding
• A relatively new welding
process, in where the MIG or
MAG welding is combined
with laser welding
– Both the laser and MAG is
involved in the melting process,
resulting in a narrow weld
– Significantly less heat input
than traditional arc welding
• Currently used:
– In panel line for butt and fillet
welds
SAW Hybrid

See INTERSHIP - Video

Laser-hybrid welding
Advantage of Laser-hybrid welding

• Laser-hybrid welding offers Arc welded deck

advantages over conventional
arc welding processes
– Lower heat input and lower
welding deformation
– Higher welding speed i.e.
productivity
Laser-hybrid welded plate
– Allows thin plate (T < 5.5 mm)
welding in shipyard environment
... but, investment cost for
equipment are still relative high
Material handling
• Conveyors
– roller, chain and
disk

• Bridge and gantry

cranes
– Lifting hook, clamp,
magnetic, vacuum
– Radio or cable
control, cab
Material handling
• Cages
• Trucks
• Transfer platforms
• Loading trailer
Material handling

• Block truck
• Air bearings
• “Walking beam”
type of transfer
beams
• Runner and
transferring
jacks