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3 Design Considerations for Aluminum Hull Structures

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3 Design Considerations for Aluminum Hull Structures /’”’”3 DESIGN CONSIDERATIONS FOR ALUMINUM HULL STRUCTURES S~UDY OF ALUMINUM BULK CARRIER This document has been approved for public release and sale; its distributions unlimited. ,,-., SHIP STRUCTURE COMMITTEE ...><.‘,- 1971 - “w.,. .- SHIP STRUCTURE COMMilTEE AN INTERAGENCY ADVISORY COMMITTEE DEDICATED TO IMPROVING THE STRUCTURE OF SHIPS MEMBER AGENCIES: ADDRESS CORRESPONDENCE TO: LJNITED STATES COAST GUARD SECRETARY NAVAL. SHIP SYSTEMSCOMMAND SHIP STRUCTURECOMMITIEE MILITARY SEALIFT COMMAND U.S. COAST GUARD HEADWAITERS MARITIME ADMINISTRATION WASHINGTON, D.C. 20591 AMERICAN BUREAU OF SHIPPING .,.. ..; .“,. SR 190 --...? The Ship Structure Committee is sponsoring research to investigate the suitability of modern structural materials for ships’ hull structures and to examine changes in design practices necessary to take advantage of the properties of these materials. This report describes an investigation of the design of an all aluminum bulk carrier. Comments concerning this report are solicited. W. F. REA, III Rear Admiral, U. S. Coast Guard Chairman, Ship Structure Committee ,.. .-!,,., 1 .-— . .._ -— ..—,.—.-.” —” ..-. .— .-—,.. SSC-218 Final Technical Report Project SR-190 “Alumin;~ Hull Feasibility Study” DESIGN CONSIDERATIONS FOR ALUMINUM HULL STRUCTURES STUDY OF ALUMINUM BULK CARRIER by C. J. Altenburg R. J. Scott Gibbs & Cox under Department of the Navy Naval Ship Engineering Center Contract No. NOO024-70-C-5138 This dbeument haz been approved for public reksa and sale; its dikkibution i; unlimited. U.S. Coast Guard Headquarters Washington, D. C. 1971 ABSTRACT The fabrication of a large aluminum hull with state of the art materials and construction techniques is shown to be technically feasible. Present 5000 series alloys have adequate properties, though additional research is required, particularly into fatigue characteristics. Ex- perience to date with existing aluminum ships has been good, though instances of cracking at welds and corrosion have been noted. Criteria for the design of the aluminum hull structure are presented and justified. Methods of fire protection and system/equipment installation are evaluated, and operational characteristics of an aluminum bulk carrier are reviewed. The designs of a large aluminum bulk carrier and an equivalent steel ship are presented and compared. The aluminum ship’s structure weighs 43 per cent less than the steel ship, and its hull is about 50 per cent more flexible. Cargo deadweight is increased 7-1/2 per cent. Cost studie’s indicate that for the same return on investment the required freight rate of the aluminum bulk carrier is higher than the equivalent steel ship, for all levels of procurement, assumed hull life, or voyage length considered. Areas for further research are presented and further investigations of large aluminum ships are proposed. ii CONTENTS PAGE I. INTRODUCTION . 1 Background . 1 Scope of Study . 3 Selection of Bulk Carrier . 3 . II. MATERIAL AND DESIGN STUDIES . 7 Review of Aluminum Alloys . 7 Operations of Existing Aluminum Ships . 37 Design Criteria for Hull Structure . , . 42 Fabrication of Large Aluminum Hulls . 58 Fire Protection . 60 Installation of Systems and Equipment , . 70 Operational Characteristics of an Aluminum Bulk Carrier . ● . 85 III. COMPARATIVE SHIP DESIGN AND EVALUATION . 86 Iv. COST STUDIES . , . !37 v. RECOMMENDED AREAS FOR FURTHER STUDY . 109 VI ● CONCLUSIONS AND RECOMMENDATIONS . 111 VII. LIST OF REFERENCES . ● . ● *... 115 APPENDICES A DETERMINATION OF LONG-TERN BENDING MOMENTS FOR ALUMINUM BULK CARRIER . 121 B EXCERPTS FROM RULES AND REGULATIONS FOR CARGO AND MISCELLANEOUS VESSELS . 124 c FIRETESTMETHODS . 127 ,.. iii LIST OF TABLES TABLE NO. PAGE 1 Principal Characteristics - M. v. C7zaZZenger . 4 2 Mechanical Properties of Aluminum Alloy Sheet and Plate. 9 3 Mechanical Property Limits of Aluminum Alloy Extrusions. -. .14 4 Static Properties of Welded Aluminum Alloys. ~ . 14 5 Relative Toughness of 5000 Series Aluminum Alloys. 25 6 Sea Water Immersion Tests (5086-H34) . 29 7 Corrosion Resistance of Aluminum Alloys to Tide Range Sea Water Immersion - Seven Years’ Exposure. 29 8 Resistance of Aluminum Alloy Weldments to Corrosion in Sea Water - Five Years’ Exposure. 29 9 Relative Corrosion Resistance of Aluminum Alloys toBulkCargoes. .31 10 Evaluation of Aluminum Alloy Characteristics . 36 11 Aluminum Bulk Carrier - Summary of Joiner Bulk- heads, Linings and Insulation in Living, Working and Stores Spaces. .63 12 Aluminum Bulk Carrier - Summary of Ceilings, Insulation and Deck Covering in Living, Working and Stores Spaces. - . .64 13 Aluminum Bulk Carrier - Additional Insulation and Deck Covering in Machinery Space . 66 14 Material Cost - Ballast System (Dollars U.S.). 77 15 !laterial Cost - Bilge System in Ballast Tanks(Dollars U.S.). 78 .. 16 Comparison of Aluminum a~d Steel Bulk Carrier Midship Sections . .. - . .-.-.90 17 Light Ship Weight Estimate - Steel Construction. 92 18 Light Ship Weight Estimate - Aluminum Construction . 92 iv LIST OF TABLES (Cent’d) TABLE NO. PAGE 19 Aluminum Bulk Carrier - Hull Structure Weight Estimate. .93 20 Aluminum Bulk Carrier - Equipment and Outfit WeightEstimate. .94 21 Aluminum Bulk Carrier - Machinery Weight Estimate. 95 22 Trim and Stability - Full Load Departure Condition (Homogeneous Cargo) . ...96 23 Trim and Stability - Ballast - Arrival Condition . 96 24 Price of Steel Bulk Carrier. ...98 25 Price of Aluminum Bulk Carrier . 98 26 Operating and Maintenance Cost Assumptions . 99 27 Comparison of Steel and Aluminum Bulk Carriers (Ck,a2Zwzger Class) - Four-Leg Voyages. , . 100 28 Comparison of Steel and Aluminum Bulk Carriers (OzzZZenger Class) - Two-Leg Voyages . ... ... 102 . 29 Comparison of Steel and Aluminum Bulk Carriers (ClzaZZenger Class) - Three-Leg Voyages . 107 LIST OF FIGURES FIGURE NO. PAGE 1 General Arrangements - M. V. Clza2Zmgm . 5 2 Midship Section - M’. V. ChaZ2enger . s . 6 3 S-N Fatigue Curves for Unwelded 5000 Series Aluminum Alloys and Structural Steel . 17 4 S-N Fatigue Curves for Welded 5000 Series Aluminum Alloys and Structural Steel . 17 5 S-N Fatigue Curves for 5083-H113 Aluminum Alloy . 18 6 S-N Fatigue Curves for 5086-H32 Aluminum Alloy . “ - “ “ 18 i’ S-N Fatigue Curves for 5456-H321 Aluminum Alloy - . ‘ . 19 8 S-N Fatigue Curves for Structural Steel . - - . 19 9 S-N Fatigue Curves for 5083-H1’13 Alloy and Mild Steel Subject to Water Spray. - . “ . “ .20 10 Recommended S-N Fatigue Curves for Welded 5000 Series Aluminum Alloys and Mild Steel for Design of5hipStructure. “ . “ . “ . “ . “ 23 11 Cracking in Way of Lapped Joint Between Flanged Plates. ● . “ . “ - .40 12 Stress-Strain Relationships for Aluminum. 49 13 Relationship Between S-N Curves and Life Cycle Hull Bending Stress for Steel and Aluminum Bulk Carrier. “ . ● . “ “. “ . “ c “ . .50 14 Stern Tube& Propeller Details 72 M. V. Ch.azlmger. ● - . - “ “ - - - . ‘ . - 15 Midship Section - Steel Bulk Carrier. 89 16 Midship Section - Aluminum Bulk Carrier Static Strength Requirements . .. “ - - . - - . .- “ ’89 17 Midship Section - Aluminum Bulk Carrier Fatigue Strength Requirements . 89 18 Typical Bulkhead- - Steel and Aluminum Bulk Carriers . 91 vi LIST OF FIGURES (Cent’d) FIGURE NO. PAGE 19 Required Freight Rate Versus Round Voyage . 103 20 Required Freight Rate Versus Ship Investment cost . 103 21 Required Freight Rate Versus Ship Life. 104 22 Annual Transport Capability Versus Round Voyage Distance. 104 23 Required Freight Rate Versus Round Voyage - Three Legs - Weight Sensitive Cargo . 109 ***** 1A Long Term Distribution of Vertical Bending Moment (For Preliminary Design). 123 cl Standard Time - Temperature Curve For Fire Tests. 128 vii SHIP STRUCTURE COMMITTEE The SHIP STRUCTURE COMMITTEE is constituted to prosecute a research program to improve the hull structures of ships by an extension of knowledge pertaining to design, materials and methods of fabrication. RADM W. F. Rea, III, USCG, Chairman Chief, Office of Merchant Marine Safety U, S. Coast Guard Headquarters Capt. J. E. Rasmussen, USN t!;!e:.S. Dillon Head, Ship Engineering Division Naval Ship Engineering Center Office of Ship Construction Maritime Administration Capt. T. J. Banvard, USN Maintenance and Repair Officer Mr. C. J. L. Scho.efer,Vice President Military, Sealift Command American Bureau of Shipping SHIP STRUCTURE SUBCOMMITTEE The SHIP STRUCTURE SUBCOMMITTEE acts for the Ship Structure Committee on technical matters by providing technical coordination for the determination of goals and objectives of the program, and by evaluating and interpreting the results in terms of ship structural design, construction, and operation. NAVAL SHIP ENGINEERING CENTER U. S, COAST GUARD Mr. P, M. Palermo - Chairman LCDR C. S. Loosmore, USCG - Secretary Mr, J. B. O’Brien - Contract Administrator CDR C. R. Thompson, USCG - Member Mr. G. Sorkin - Member CDR J. W. Kime, USCG - Alternate Mr. H. S. Sayre - Alternate CDR J. L. Coburn - Alternate Mr. I. Fioriti - Alternate NATIONAL ACADEMY OF SCIENCES MARITIME ADMINISTRATION Mr. R. W. Rumke, Liaison Mr. F. Dashnaw - Member Prof. R. A. Yagle, Liaison Mr. A. Maillar - Member Mr. R. Falls - Alternate SOCIETY OF NAVAL ARCHITECTS & MARINE Mr. Raymond F. Coombs - Alternate ENGINEERS AMERICAN BUREAU OF SHIPPING Mr. T. M. Buermann, Liaison Mr. S. G. Stiansen - Member Mr. F. J. Crum - Member AMERICAN IRON AND STEEL INSTITUTE OFFICE OF NAVAL RESEARCH Mr. J. R. Lecron, Liaison Mr. J. M. Crowley - Member Dr. W. G. Rauch - Alternate BRITISH NAVY STAFF NAVAL SHIP RESEARCH & DEVELOPMENT CENTER Dr. V. Flint, Liaison
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