Table Of ContentHYBRID
SHIP HULLS
HYBRID
SHIP HULLS
Engineering Design
Rationales
VLADIMIR M. SHKOLNIKOV
Principal Investigator
Beltran Inc., New York, USA
AMSTERDAM (cid:129) BOSTON (cid:129) HEIDELBERG (cid:129) LONDON
NEW YORK (cid:129) OXFORD (cid:129) PARIS (cid:129) SAN DIEGO
SAN FRANCISCO (cid:129) SINGAPORE (cid:129) SYDNEY (cid:129) TOKYO
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PREFACE
The development of novel structural systems is inconceivable without
advanced materials aimed at improving service performance for a new
demand. As with everything in nature composed of a mixture of materials
that work well together, two or more dissimilar material systems may be
employed in concert to form a hybrid engineering structure that balances
theenhancedserviceperformanceofthestructurewithitsfeasibilityandcost
efficiency.
Oneofthemostcommonstructuralhybridsbeingexploitedtodaycom-
bines metals with polymer matrix composites. A characteristic example of
this is a warship’s primarily metal hull with composite structural compo-
nents.Whileupgradingfunctionalandoperationalcapabilities,ahybridhull
significantlydiffersfromaconventionalmonomaterialhull,whichiseither
fully metal or fully composite. The encountered distinctions pertain to the
two major factors governing a structure’s engineering, material processing
and structural behavior. Jointly, these distinctions engender considerable
peculiaritiesofengineeringroutinesthatneedbeascertainedforaneffective
implementation of the projected hybrid structure.
The present work identifies specific traits intrinsic to hybrid structural
systems and outlines design rationales that maximize functional and opera-
tional effectiveness of the hybrids. It is primarily dedicatedto the advance-
mentofnavalstructuresandisbaseduponexperienceacquiredoverdecades
of engineering and operation of naval composite and hybrid structures.
Aside from a direct military destination, the imparted data might also be
usefulforadiversityofheavy-dutystructuralsystemsthroughoutnon-naval
marine, aerospace, automotive, wind-power generation, and other indus-
tries striving to maximize service performance, weight efficiency, cost
effectiveness, and safety of structural operation.
The book chapters impart diverse aspects of hybrid structure engineer-
ing, specifically as follows.
Chapter 1 introduces the grounds for hybrid hull development and
peculiarities inherent to hybrid structure engineering. It also provides an
overview of the history of composite shipbuilding and summarizes the
lessons learned from preceding experience, the rational adaption of which
facilitates success in hybrid hull development.
vii
viii Preface
Chapter2benchmarksrepresentativeexamplesofwarshipswithhybrid
hulls, distinguishing two major categories of composite applications for
primarilymetalnavalvessels:topsidestructuresofsurfaceshipsandoutboard
(light hull) submarine structures.
Chapter3enlightensspecificfacetspertinenttoengineeringofmaterial-
transition structures, hybrid (metal-to-composite) joints in particular, and
outlines design rationales for selection of robust and structurally efficient
technical solutions.
Chapter 4 presents results of the recent development of an emerging
bonded-pinned(Comeld-2)hybridjoiningtechnologythatappearssuperior
to the state-of-the-art hybrid joining options for heavy-duty applications
available to date.Chapter 4also delineateseconomicaspects of hybrid hull
concept implementation with utilization of Comeld-2.
Chapter 5 addresses methodological aspects of serviceability evaluation
of composite and hybrid structures undergoing long-term changing
force-ambient operational exposures.
Chapter 6 identifies and outlines the targets for prospective develop-
ments with regard to beneficial utilization of the hybrid structure concept,
including those beyond naval shipbuilding.
The appendix of the book presents a few MatLab codes exemplifying
evaluation of serviceability of a composite structure undergoing assorted
force-temperature exposures.
ACKNOWLEDGMENTS
TheauthorexpresseshisdeepappreciationtoElsevierforitssteadfastassis-
tance and guidance during preparation of this manuscript. The author
extendshisspecialthankstoHayleyGray,SeniorAcquisitionsEditor;Cari
Owen, Editorial Project Manager; Hop Wechsler, Permissions Helpdesk
Manager;LisaM.Jones,ProjectManager;andPaulGottehrer,Copyeditor.
Aprevailingpartofthepresenteddatareflectsoutcomesoftheauthor’s
investigations primarily dedicated to the advancement of assorted naval
platforms utilizing structural composites. These were performed in part in
Russia prior the author’s move to the U.S. in August 1995 and in part
afterward.
The author gratefully acknowledges the sponsorship provided by both
the Russian and U.S. governments, as well as the productive cooperation
of his colleagues in both countries.
ix
CHAPTER 1
Premises of Hybrid Hull
Implementation
1.1 TRENDS IN DEMAND FOR COMPOSITE AND HYBRID
STRUCTURES
Developmentofnovelstructuralsystemsisinconceivablewithoutadvanced
materials capable of facilitating service performance related to a new
demand. As with everything in nature composed of a mixture of materials
that work well together, two or more dissimilar material systems may be
employedinconcerttoformaheterogeneous,hybridstructurethatenables
a rational balance of enhanced performance with feasibility and cost effi-
ciency of the new structure. One of the most common structural hybrids
beingexploitedcombinesmetalswithpolymermatrixcomposites(PMCs).
StructuralutilizationofPMCsisextensiveandrapidlyexpandingtoday.
This is due to a combination of the structural and physical properties of
PMCs that enables substantial advancement of assorted structural systems.
Astructure’sweightreductionalliedwiththehighspecificstrengthofstruc-
tural PMCs; an opportunity to provide a complex streamlined shape, con-
siderably simplifying employed manufacturing processes; and great
corrosion/fouling resistance in a harsh operation environment, allowing
forpracticallyeffortlessmaintenance—theseandotheradvantagesaredriv-
ing the exceptional popularity of PMCs for a diversity of structural
applications.
Among the major beneficiaries are watercraft, aircraft, and spacecraft;
automobiles and other ground vehicles; bridges, causeway floating plat-
forms, and offshore oil/gas rigs; pipelines and pressure tanks; wind turbine
blades; and so on. Warships and other naval platforms represent a worth-
while example of the structural hybrids operated on, under, and above
the sea surface.
Despitethemultiplegains,lackofmagnetismwasinfactaprimeinspiration
forthenavalapplicationofPMCs,particularlyforminecountermeasuresves-
sels(MCMVs).Enhancedstealthperformanceisanotheradvantagecallingfor
expanded use of PMCs for warships. Not only relatively small and midsize
©2014ElsevierInc.
HybridShipHulls Allrightsreserved. 1
2 HybridShipHulls
warships, such as MCMVs and corvettes, which typify full-composite naval
vessels,benefitgreatlyfromPMCutilization.Large,primarilymetal-hullships
such as destroyers and missile submarines, for which a full-composite hull is
impractical,mayalsobebeneficiaries.Forinstance,adestroyer’ssuperstructure
madeofaPMCiscapableofabsorbingelectromagneticemanationsfromradar
andtransformingthesignatureofthevessel,simultaneouslysignificantlyreduc-
inghertopweight(Arkhipovetal.,2006;Hackett,2011;Lackeyetal.,2006).
In general, such key advantages as weight saving, augmented
deadweight-to-displacement ratio, increased speed and/or cruising range,
improvedstability,corrosionprevention,enhancedpropulsioncharacteris-
tics,andimprovedsignaturecontrolmayallensuefromimplementationofa
hybrid hull combatant ship.
Weightsaving,augmenteddeadweight-to-displacementratio,increasedspeed
and/or cruising range, improved stability, corrosion prevention, enhanced
propulsion characteristics, and improved signature control; all could be
facilitatedbyimplementationofthehybridhullconceptforacombatantship.
Essentially,anystructuralcomponentofahybridhullmightbemadeof
structural PMCs, including but not limited to hull shell panels, bulkheads,
platforms,thedeckhouse,thesuperstructure,andfoundationsformachinery
and equipment, as well as other heavily loaded ship structures, including
rudders and structural components of water jet propulsion systems, such
as the outlet, pump housing, housing inlet, and inlet tunnel.
Itshouldbenotedthatalongwiththeprimarystructuralmaterial,metalsand
PMCs,anassortmentofancillarymaterialsmaybeusedwithinahybridstruc-
ture.Theseincludeavarietyoflight-weightcorematerialspertinenttosand-
wich panels, rubbers (for acoustical enhancement of structural panels), and
ceramics(usefulforenhancementofballisticprotectionofastructure’spanel).
Aseriesofrecentpatentsandtechnicalpapersenlightenthehybridhull
notion with regard to the major structural components of a primarily
metal naval surface vessel—bow, stern, and midship side panels, as well as
topsidestructures.Thefollowingrepresentanarrayofrelatedrecentpatents
(Aleshin et al., 2011; Barsoum, 2002, 2005; Critchfield et al., 2003;
Kacznelson et al., 2009; Maslich et al., 2009; Shkolnikov, 2011, 2013)
andtechnicalpapers(Barsoum,2003,2009;Bulkinetal.,2011;Critchfield
et al., 1991; Horsmon, 2001; Kudrin et al., 2011; Mouritz et al., 2001;
Potter, 2003; Shkolnikov et al., 2009).
Premisesofhybridhullimplementation 3
Asforrewardingapplicationsforsurfacevessels,hybridstructuresarealso
favorable for submarines, particularly in terms of their outboard structural
components. The benefits pertaining to PMCs’ submarine application
include increased sonar efficiency, avoidance of intricate demagnetization
procedures relevant to complex-shape structures, and simplified trimming
and ballasting operations. For these reasons, a sonar dome, ballast cisterns,
superstructures, sail (fairing), fins, propulsors, launch tubes, and hatches
areallgoodcandidatesforreplacementofmetalwithPMCtoenablesignif-
icant enhancement of a sub’s structural and combat efficiency.
Figure 1.1 depicts a generalized hybrid hull architecture applicable to
both major categories of naval ships, surface vessels and submarines, for
which the hybrid hull option might be superior.
The white areas indicate locations of composite structural components
potentiallybeneficialtotheserviceperformanceofthesemetalnavalvessels.
Besides technical advantages, a PMC application for a primarily metal
vessel may facilitate considerable cost savings. Although a hybrid hull con-
struction itself is typically somewhat more expensive than a conventional
monotonous metal hull, the ensuing significant weight savings ultimately
provides a noticeable reduction of the ship’s construction cost. Resistance
to both corrosion and fouling in turn dramatically lowers maintenance
expenses, greatly contributing to overall ownership cost savings.
1.2 HYBRID HULL PECULIARITIES
Evidently, a hybrid structure comprises merely metal and composite
mono-material components along with a distinctive heterogeneous
material-transition structure. For some structural units, such as a hull shell,
mono-material components represent the prevailing part of the hybrid
structure, while the material transition typically embodies just a hybrid
(composite-to-metal) joint. For other parts, such as a ballistic-protection
paneloracompositepipelinewithametallicload-sharingliner,thematerial
transition essentially represents the entire hybrid structure. For both these
major alternatives, the pursued heterogeneity, while capable of upgrading
functional and operational performance, considerably affects both
manufacturing technology and structural behavior of a hybrid ship hull,
requiringacertainrevisionofconventionalengineeringroutines,including
a structural design optimization, structure analysis and strength reconcilia-
tion, and material processing.
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Figure1.1 Generalizedhybridhullarchitecture.
