• 2017 September 12 08:34

    3D printed ship’s propeller takes step closer to completion

    A prototype of the world’s first class approved ship’s propeller has been produced using 3D printing techniques. The 1,350mm diameter propeller – named WAAMpeller – is the result of a cooperative consortium of companies that includes DAMEN Shipyards Group, RAMLAB, Promarin, Autodesk and Bureau Veritas.

    The WAAMpeller was fabricated from a Nickel Aluminium Bronze (NAB) alloy at RAMLAB (Rotterdam Additive Manufacturing LAB) in the Port of Rotterdam. The propeller was produced with the Wire Arc Additive Manufacturing (WAAM) method using a Valk welding system and Autodesk software. The triple- blade structure uses a Promarin design that is used on Damen’s Stan Tug 1606. With production complete, the WAAMpeller will be CNC milled at ‘Autodesk’s Advanced Manufacturing Facility in Birmingham, UK’.

    This prototype 3D printed propeller represents a steep learning curve of the understanding of material properties. “This is because 3D printed materials are built up layer by layer,” says Kees Custers, Project Engineer in Damen’s R&D department. “As a consequence, they display different physical properties in different directions – a characteristic known as anisotropy. Steel or casted materials, on the other hand, are isotropic – they have the same properties in all directions.”

    Because of this critical difference, one of the first steps was to carry out extensive testing of the material properties of the printed material to ensure compliance to Bureau Veritas standards. “This involved printing two straightforward walls of material – then using a milling machine to produce samples for lab testing of tensile and static strengths.” It can also be said that the 400kg WAAMpeller sets a milestone in terms of 3D printing production techniques.

    “The challenge has been to translate a 3D CAD file on a computer into a physical product. This is made more complex because this propeller is a double-curved, geometric shape with some tricky overhanging sections,” explains Mr Custers. Yannick Eberhard from Promarin’s R&D department adds that “the transformation from a semi-automatic to robotic processing is the solid foundation for even more complex and reliable future propeller designs“.

    “Material characterization and mechanical testing have been an important part of this project,” says Wei Ya, Postdoctoral Researcher from the University of Twente at RAMLAB. “We have to make sure that the material properties meet the needs of the application. Material toughness, for example – ensuring that the propeller is able to absorb significant impact without damage.”

    “But we have also been working towards optimising the production strategy for 3D metal deposition. This includes bead shape and width, as well as how fast we can deposit the printed material.” Highlighting RAMLAB’s capacity to print objects with maximum dimensions of 7x2x2 metres, Mr Ya says: “For large scale 3D metal deposition, the WAAMpeller is really ground-breaking for the maritime industry.”

    “This technology is a fundamental change in the concept of how we make things. With additive manufacturing, you can print most metallic components that are needed in principle. There is so much potential for the future – these techniques will have a big impact on the supply chain.” Class approval This first prototype WAAMpeller will be used for display purposes, and planning for a second example is already underway.

    “We start production of a second propeller with class approval later next month –  using all the lessons we have learned over the past few months,” notes Mr Custers. “We are aiming to install this second one onto one of our tugs later this year.” 

    Damen Shipyards Group

    Damen Shipyards Group operates 33 shipbuilding and repair yards, employing 9,000 people worldwide. DAMEN has delivered more than 6,000 vessels in more than 100 countries and delivers some 180 vessels annually to customers worldwide. Based on its unique, standardised ship-design concept DAMEN is able to guarantee consistent quality. Damen’s focus on standardisation, modular construction and keeping vessels in stock leads to short delivery times, low ‘total cost of ownership’, high resale values and reliable performance. Furthermore, DAMEN vessels are based on thorough R&D and proven technology. DAMEN offers a wide range of products, including tugs, workboats, naval and patrol vessels, high speed craft, cargo vessels, dredgers, vessels for the offshore industry, ferries, pontoons and superyachts. For nearly all vessel types DAMEN offers a broad range of services, including maintenance, spare parts delivery, training and the transfer of (shipbuilding) know-how. DAMEN also offers a variety of marine components, such as nozzles, rudders, anchors, anchor chains and steel works. DAMEN Shiprepair & Conversion (DSC) has a worldwide network of sixteen repair and conversion yards of which twelve are located in North West Europe. Facilities at the yards include more than 50 floating and (covered) drydocks, the largest of which is 420 x 90 metres, as well as slopes, ship lifts and indoor halls. Projects range from the smallest simple repairs through Class’ maintenance to complex refits and the complete conversion of large offshore structures. DSC completes around 1,350 repair and maintenance jobs annually, both at yards as well as in ports and during voyage.

2018 March 17

06:48 Seatrade convicted for trafficking toxic ships

2018 March 16

18:06 Rijkswaterstaat awards Afsluitdijk project to Levvel consortium
17:36 HHLA Container Terminal Burchardkai handles new record ship
17:05 ICS publishes latest Flag State Performance Table
16:51 Vladimir Putin inspected the completed new road section of the Crimean Bridge
16:35 Wison successfully delivers the global largest single cracking furnace module
16:20 GTT announces the end of the test phase of its new LNG brick® technology
16:05 Fincantieri starts building of ultra-luxury cruise ship for Regent Seven Seas Cruises
15:30 Caterpillar Marine announces first European IMO Tier III tugboat
15:03 Throughput of port Kavkaz up 67% to 4.3 million tonnes in 2M’18
14:39 Port of Hamburg proves effectiveness in handling mega-carriers
14:05 Training for port facility security staff arranged in the Dominican Republic
13:42 Multipurpose Reloading Complex takes lead in the industry
13:20 Karachi Shipyards & Engineering Works delivers two Damen Stan Patrol 1605 FRP patrol boats to Pakistan Customs
13:17 Bunker prices continue going down at the port of Novorossiysk, Russia (graph)
12:51 52 icebreaker escort operations performed in eastern part of Gulf of Finland during 24 hours on March 15-16
12:28 Seaports of Russia’s Azov Sea Basin handled 16.77 million tonnes of cargo in winter 2017-2018, up 63.8% Y-o-Y
12:04 Latin America maritime cooperation centre launched
11:40 Vympel Shipyard laid down second armament support ship of Project 20360М for RF Defence Ministry (photo)
11:15 Vostochny Port JSC develops railway infrastructure under its Phase 3 project (photo)
10:52 IMO joined leading oil spill experts to discuss future issues concerning oil spill preparedness, response and restoration
10:27 Brent Crude futures price down 0.11% to $65.05, Light Sweet Crude – down 0.05% to $61.16
10:09 Panama Canal signs agreement with Association of Soybean and Corn Producers of Mato Grosso
09:48 IMO is looking at safety aspects of on shore power supply to ships
09:34 Bunker prices are flat at the Port of Saint-Petersburg, Russia (graph)
09:16 Baltic Dry Index down to 1,150 points
09:03 Damen unveils Multi Cat Water Injection Dredger

2018 March 15

18:25 CMA CGM announces FAK rates from Asia to the Mediterranean
18:11 ICS releases latest Flag State Performance Table (with new criteria included)
18:05 Fincantieri will cooperate with Barzan Holdings
17:57 Throughput of port Kaliningrad in 2M’18 up 16% Y-o-Y to 2.32 million tonnes
17:35 Second Sanmar Voith Schneider Propeller tug joins sister in Israel
17:20 Throughput of port Vyborg up 19% to 197,800 tonnes in 2M’18
17:05 Seaspan acquires Greater China Intermodal Investments LLC
17:02 MABUX: global bunker market still in 'wait-and-see' mood
16:35 DP World announces strong financial results for 2017
16:16 Throughput of port Vysotsk down 5% to 3.06 million tonnes in 2M’18
16:05 ECSA and WSC call for the revision of the Reporting Formalities Directive to improve the efficiency of maritime transport
15:39 Port of Oakland imports up 14.9 percent in February 2018
15:31 Sanmar orders 42 Rolls-Royce thrusters
15:22 Coastal facilities and hydraulic engineering structures under FNPP project in Chukotka to be completed in August 2019
15:07 Port of Dover awards major contract for new Refrigerated Cargo Terminal
14:33 Yang Ming to launch new Japan-Malaysia-Vietnam direct service
14:11 Throughput of port Primorsk in 2M’18 down 32% Y-o-Y to 7.47 million tonnes
13:50 Throughput of port Ust-Luga up 6% to 16.59 million tonnes in 2M'18
13:25 VARD secures contract for the construction of one fishing vessel for Remøybuen AS
13:12 Throughput of Big Port St. Petersburg up 11% to 9.01 million tonnes in 2M’18
12:30 Paweł Jakubowski appointed as President of Polskie LNG S.A. Management Board
11:45 Freeport of Riga is getting ready for new cruise ship season
11:44 MOL announces delivery of the Beluga Ace, 1st next-generation FLEXIE series car carrier
11:23 34 icebreaker escort operations performed in eastern part of Gulf of Finland during 24 hours on March 14-15
11:00 Bunker prices are going up at the Far East ports of Russia (graph)
10:38 Marine Recruiting Agency and Corporate University “Norilsk Nickel” take on joint educational project
10:14 Brent Crude futures price up 0.05% to $64.92, Light Sweet Crude – up 0.11% to $61.03
09:49 Arctic Council will gather in Levi, Finland on 22-23 March 2018
09:17 Baltic Dry Index down to 1,169 points

2018 March 14

18:26 Port of Antwerp sets up maritime training institute in Brazil
18:06 Port of Oakland releases a new 5-year strategic plan
17:55 Baltic Workboats delivers ten more 15m Baltic wave piercing pilot boats to Denmark pilots stations
17:36 Fincantieri upgrades ultra-luxury cruise ship Silver Spirit