Laser Panel Manufacturing Program

This SBIR Phase II project addresses both the welding of butt joints in plate panels for ships and the manufacture of highly weight-efficient structural sandwich panels for shipbuilding applications. The Phase I project established the technical and financial viability of the Laser/Gas Metal Arc Welding (LGMAW) process to manufacture flat plate blankets ready for further stiffening. A major task in Phase II is the completion of a prototype system to be used in shipyards. In addition, Phase II activities will encompass the design and construction of a manufacturing system for lightweight sandwich panels for advanced performance in combatant and other vessels. Phase I economic analysis predicted a two-year payback for a laser-based butt welding system, and an increase to throughput of nearly 40%. Interest in the system is strong with US major shipyards, since plate butt welding is today a major cost-driver in shipbuilding. Equally, structural sandwich panels have been analyzed for a wide variety of trial applications, showing a weight advantage of up to 50% in total structural weight compared to beam-stiffened plate structures. However, prior efforts have not resulted in commercialization, due to high manufacturing costs. This project will develop methodologies leading to significant cost reductions.