Report

Teaser, summary, work performed and final results

Periodic Reporting for period 1 - RAMSSES (Realisation and Demonstration of Advanced Material Solutions for Sustainable and Efficient Ships)

Teaser

Innovative materials and their wider use are crucial to improve the life cycle performance of European built ships, to reduce their environmental footprint, to make the industry more competitive and to create and maintain employment. Despite considerable progress and...

Summary

Innovative materials and their wider use are crucial to improve the life cycle performance of European built ships, to reduce their environmental footprint, to make the industry more competitive and to create and maintain employment. Despite considerable progress and commercial applications in recent years, the use of advanced materials on sea is lagging behind the potential. RAMSSES wants to overcome existing obstacles by pursuing 3 main objectives:
1: Design and build 13 market driven Demonstrator Cases (Demos) to show potential and maturity of innovative materials. Demos cover the entire maritime supply chain (components, equipment, integration in complex products, repair).
2: Prove full technical feasibility (both in production and operation) and economic viability of the solutions by doing tests and LCPA studies.
3: Support the innovation capabilities of the consortium members and the maritime sector. Main ingredients are a sustainable network and an innovation platform which is based on a knowledge repository for material innovation in maritime.

Work performed

Objective 1: Demos identified the specific requirements, developed the product design and related manufacturing processes. Short details per Demo:
\'Modular Light System for Less Critical Internal Walls and superstructure\': Standardised solution for interior walls developed, meeting fire and comfort requirements. However, the physical demonstrator will be a complete catamaran, built up of sandwiches with a truss structure core, using a robotised filament winding process.
\'Lightweight Components for High Loads and Fire Class\': Focus on bio-based, fire retardant materials, applied for decks, walls and ceilings on passenger vessels. Requirements for testing of fire, mechanical and noise damping properties were derived. Alternative application outlined, e.g. house boats.
\'Propeller blades by additive manufacturing\': A 3D printing technology (WAAM) is addressed, producing hollow propeller blades with improved performance. A 1/3 scale model was produced to identify manufacturing area for the hollow blade which represent the main geometric singularities.
\'Lightweight rudder flap’: replacing steel by composite material to improve structural properties, hydrodynamics, and maintenance; new production procedures defined, structural strength investigated.
\'Integration of system for internal walls and superstructure of cruise ship into shipyard process\' integrates FRP in yard production. First case will cover lightweight, non-load bearing walls; FRP material identified, composite walls designed, and yard assembly scenarios defined.
\'Modular Decks for RoRo vessel\': optimising car carriers’ design and production using composites and pultruded profiles; new panel and grillage design developed; integration of pultruded profiles to be studied due to different profile dimensions and safety issues (fire, impact).
\'Lightweight wall for workboats\': composites sandwich panels for deckhouses and superstructures; assessment of 2 options covering structural capability and production aspects; development of the detailed design in parallel.
\'Composite superstructure module on steel deck for multi purpose vessels\': Application of a new composite structure with the challenge to join the structure to steel; requirements were listed and risk assessment undergone, taking into account the composite stack layer, structural strength and bonded design for the superstructure.
\'Custom Made Hull for Offshore vessel\': aim to build a full scale hull section demonstrator (6m x 6mx 3m) by doing 6 m infusion; baseline design and risk assessment done; strategy for vertical infusion ongoing.
’Multi material lightweight cabin for passenger ships’ proposes a new fabrication method for cabins to save mass and to lower the center of gravity. Promising resistance and fire test results for the material Zaltex.
‘Highly loaded structural detail from HSLA in passenger and research vessel’ (FC, IT): The welding process of HSLA is investigated, including the introduction of post-welding techniques (friction stir, over-lamination) for better fatigue. Process parameters are being investigated using DoE.
’Lightweight decks using HSLA in cruise ships’: The basic design of a large scale Demo using HSLA thin plates was done and pre-tests including welding tests, hardness, microstructure, surface roughness, residual stress investigations, static and fatigue tests have been defined.
‘Composite overlay to repair and improve metallic and non metallic structures’ is a Demo focusing on patch repair using Composite overlays. Close collaboration with 3 different Demos is foreseen to show the technology.
Objective 2: Activities are focusing on assessing both technical (including safety) and economic aspects to show that Demos are viable and competitive.
Based on discussions with the Demos, critical technical properties, applicable rules and acceptance criteria were identified. Test requirements were established. HAZID workshop will be undertaken with Demo teams to make sure that

Final results

As an industry driven Project, RAMSSES has a clear focus on solutions with a clear business potential. Demo leaders’ expectations are expressed with statements in the public Deliverable D6.1. Assessing the actual achievement of the expected impact will be part of the envisaged LCPA studies.
A positive impact on socio-economic and environmental fields is also envisaged and will be assessed during the coming Periods. Lightweight materials help reducing the mass of ship structures, thus increasing payload and/or reducing fuel consumptions and emissions. Furthermore, enhancing knowledge about the use of new materials will maintain and strengthen the compatibility of the European maritime Industry.

Website & more info

More info: http://ramsses-project.eu/.