Periodic Reporting for period 3 - RAMSSES (Realisation and Demonstration of Advanced Material Solutions for Sustainable and Efficient Ships)
Berichtszeitraum: 2020-06-01 bis 2021-11-30
The use of novel materials helps improving the performance of European built ships, reducing the environmental footprint, making the industry more competitive and safeguarding employment. Despite considerable progress and commercial applications in recent years, the use of advanced materials on sea is lagging behind the potential. RAMSSES’s 3 main objectives and main achievements are:
1: Design and build 13 market driven Demonstrator Cases (Demos) to show potential and maturity of innovative materials. Cover the entire maritime supply chain (components, equipment, integration in complex products, repair)
2: Prove full technical feasibility in production and operation, and economic viability of the solutions by testing and Life Cycle Performance Assessment (LCPA)
3: Support the maritime sector's innovation capability, e.g. by a sustainable network, an innovation platform, and contributions to rules development
Related main results:
1. Demos show great versatility of application opportunities and their market potential is evident; remaining R&D needs are related particularly to newer technologies such as 3D printing of large structures; qualification for FRP in SOLAS ships is still a challenge
2. Assessment campaigns were successful; future LCPA studies will put more emphasis on circularity aspects
3. E-LASS is nowadays the one-stop-shop for the European maritime lightweight community. For the perennial regulation development process, RAMSSES has provided important impulses
1: Design and build 13 market driven Demonstrator Cases (Demos) to show potential and maturity of innovative materials. Cover the entire maritime supply chain (components, equipment, integration in complex products, repair)
2: Prove full technical feasibility in production and operation, and economic viability of the solutions by testing and Life Cycle Performance Assessment (LCPA)
3: Support the maritime sector's innovation capability, e.g. by a sustainable network, an innovation platform, and contributions to rules development
Related main results:
1. Demos show great versatility of application opportunities and their market potential is evident; remaining R&D needs are related particularly to newer technologies such as 3D printing of large structures; qualification for FRP in SOLAS ships is still a challenge
2. Assessment campaigns were successful; future LCPA studies will put more emphasis on circularity aspects
3. E-LASS is nowadays the one-stop-shop for the European maritime lightweight community. For the perennial regulation development process, RAMSSES has provided important impulses
Objectives 1, 2: Design and processes for the Demos were developed successfully. Technical assessment (fire properties being the largest challenge) and LCPA yielded convincing results:
Modular Light System for Less Critical Internal Walls and superstructure: A solution, allowing for standardised panels as well as production of customisable products, meeting fire and comfort requirements, and an ultra-light, zero emission catamaran was built, made of sandwiches with a truss structure core by 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. Promising fire and mechanical tests results, as well as practical use in several of the shipyards’ demos (see below).
Propeller blades by additive manufacturing: Hollow, lightweight blades with improved hydrodynamic and vibration performance produced by WAAM. Metallurgical and mechanical results satisfying, corrosion behaviour better than casting material with same chemical composition.
Lightweight rudder flap: Considerable weight reduction by a new design concept replacing steel by composite material; production processes developed; test campaign demonstrated the system’s readiness for class approval.
Integration of system for internal walls and superstructure of cruise ship into shipyard process: Design and assembly concept for non-load bearing walls and two Demo structures (onshore/on-board); comprehensive fire test campaign.
Modular Decks for RoRo vessel: Optimised design for car carriers with composite panels and pultruded profiles fulfilling all fire and mechanical requirements; well-balanced production concept including the supply chain and the assembly strategy.
Lightweight wall for workboats: Composites sandwich panel for a sunroof, making use of one of the Components Demo, foreseeing various individual design details and integration of functions.
Composite superstructure module on steel deck for multipurpose vessels: New composite structure with 60% less weight, including a vacuum infusion process, adhesive bonding to the steel structure below, and a QM concept involving SHM.
Custom Made Hull for Offshore vessel: Capability to design, produce and market complete composite vessels (L>85 m) complying with SOLAS and class regulations acquired. Developments included a special resin for vacuum infusion of 6 m high structures and new methods for full scale mechanical testing.
Multi material lightweight cabin for passenger ships: Six-face cabin module with reduced weight, costs, production time, maintenance and refurbishment effort, along with a novel ship structure architecture. Next step: fill the remaining gap to pass fire tests.
Highly loaded structural details from HSLA steel in passenger and research vessels: Investigation and optimisation (based on DoE) of the welding process of HSLA and post-welding techniques (friction stir, over-lamination) for better fatigue properties.
Lightweight decks using HSLA in cruise ships: High-strength steel and advanced manufacturing technology combined to develop high quality products. Fatigue tests were done using samples from the full-scale demonstrator (a deck structure combining thin and thick plates).
Composite overlay to repair and improve metallic and non-metallic structures: Focus on patch Composite overlays for 3 RAMSSES Demos to show the technology for crack arresting, structure repair and improve fatigue behaviour.
Objective 2:
Technical and safety aspects: Based on discussions with the Demos, critical technical properties, applicable rules and acceptance criteria were identified. Test requirements were established. HAZID workshops to make sure that solutions provide equivalent safety were done and material tests took place, as explained above.
Economic/ecologic aspects: LCPA was performed for all Demo cases.
Objective 3: Activities were centred around the organisation of communication and information flows:
Dissemination measures (website, videos, conference papers etc) were accompanied by the creation of a sustainable network, building on the existing E-LASS network – result: 10 public RAMSSES/E-LASS seminars, 7 specific measures to add substantial value to E-LASS. One of the measures is an innovation platform for innovative materials and maritime applications which was launched by RAMSSES. Various projects’ results, test reports, certificates, LCPA models, external publications are shared, thus helping designers finding solutions for future applications. Upcoming projects will be encouraged to share their information in the platform as well.
A Technology Transfer Group (TTG) and a Maritime Advisory Group (MAG) were installed. TTG was a forum for knowledge exchange with other sectors' experts; 3 TTG workshops on selected topics took place. The MAG comprised 11 members (including an association); 3 MAG workshops took place.
As an initiative towards opening the approval process for innovative materials, RAMSSES presented the `Smart Track to Approval` concept during a meeting of the IMO Sub Committee for Ship Design and Construction (SDC7). A discussion process emerged which is ongoing beyond RAMSSES, dealing with the need to review interim guideline MSC.1/Circ.1574 for the use of FRP material in ships and to submit any proposals to that effect to SDC.
Modular Light System for Less Critical Internal Walls and superstructure: A solution, allowing for standardised panels as well as production of customisable products, meeting fire and comfort requirements, and an ultra-light, zero emission catamaran was built, made of sandwiches with a truss structure core by 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. Promising fire and mechanical tests results, as well as practical use in several of the shipyards’ demos (see below).
Propeller blades by additive manufacturing: Hollow, lightweight blades with improved hydrodynamic and vibration performance produced by WAAM. Metallurgical and mechanical results satisfying, corrosion behaviour better than casting material with same chemical composition.
Lightweight rudder flap: Considerable weight reduction by a new design concept replacing steel by composite material; production processes developed; test campaign demonstrated the system’s readiness for class approval.
Integration of system for internal walls and superstructure of cruise ship into shipyard process: Design and assembly concept for non-load bearing walls and two Demo structures (onshore/on-board); comprehensive fire test campaign.
Modular Decks for RoRo vessel: Optimised design for car carriers with composite panels and pultruded profiles fulfilling all fire and mechanical requirements; well-balanced production concept including the supply chain and the assembly strategy.
Lightweight wall for workboats: Composites sandwich panel for a sunroof, making use of one of the Components Demo, foreseeing various individual design details and integration of functions.
Composite superstructure module on steel deck for multipurpose vessels: New composite structure with 60% less weight, including a vacuum infusion process, adhesive bonding to the steel structure below, and a QM concept involving SHM.
Custom Made Hull for Offshore vessel: Capability to design, produce and market complete composite vessels (L>85 m) complying with SOLAS and class regulations acquired. Developments included a special resin for vacuum infusion of 6 m high structures and new methods for full scale mechanical testing.
Multi material lightweight cabin for passenger ships: Six-face cabin module with reduced weight, costs, production time, maintenance and refurbishment effort, along with a novel ship structure architecture. Next step: fill the remaining gap to pass fire tests.
Highly loaded structural details from HSLA steel in passenger and research vessels: Investigation and optimisation (based on DoE) of the welding process of HSLA and post-welding techniques (friction stir, over-lamination) for better fatigue properties.
Lightweight decks using HSLA in cruise ships: High-strength steel and advanced manufacturing technology combined to develop high quality products. Fatigue tests were done using samples from the full-scale demonstrator (a deck structure combining thin and thick plates).
Composite overlay to repair and improve metallic and non-metallic structures: Focus on patch Composite overlays for 3 RAMSSES Demos to show the technology for crack arresting, structure repair and improve fatigue behaviour.
Objective 2:
Technical and safety aspects: Based on discussions with the Demos, critical technical properties, applicable rules and acceptance criteria were identified. Test requirements were established. HAZID workshops to make sure that solutions provide equivalent safety were done and material tests took place, as explained above.
Economic/ecologic aspects: LCPA was performed for all Demo cases.
Objective 3: Activities were centred around the organisation of communication and information flows:
Dissemination measures (website, videos, conference papers etc) were accompanied by the creation of a sustainable network, building on the existing E-LASS network – result: 10 public RAMSSES/E-LASS seminars, 7 specific measures to add substantial value to E-LASS. One of the measures is an innovation platform for innovative materials and maritime applications which was launched by RAMSSES. Various projects’ results, test reports, certificates, LCPA models, external publications are shared, thus helping designers finding solutions for future applications. Upcoming projects will be encouraged to share their information in the platform as well.
A Technology Transfer Group (TTG) and a Maritime Advisory Group (MAG) were installed. TTG was a forum for knowledge exchange with other sectors' experts; 3 TTG workshops on selected topics took place. The MAG comprised 11 members (including an association); 3 MAG workshops took place.
As an initiative towards opening the approval process for innovative materials, RAMSSES presented the `Smart Track to Approval` concept during a meeting of the IMO Sub Committee for Ship Design and Construction (SDC7). A discussion process emerged which is ongoing beyond RAMSSES, dealing with the need to review interim guideline MSC.1/Circ.1574 for the use of FRP material in ships and to submit any proposals to that effect to SDC.
As an industry driven Project, RAMSSES had a clear focus on solutions with a business potential. End users’ expectations and information on each result’s actual impact on socio-economic and environmental fields can be obtained from the public report D6.6 and the final brochure (both available on the project website).
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 Europe's maritime Industry.
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 Europe's maritime Industry.