Hybrid Laser-Welded Metallic Sandwich Panel Technology Applied to DDG 1000

Daniel L. Winterscheidt
NMC Program Director



The Navy is seeking solutions to reduce weight and lower the center of gravity for surface ships to improve their performance at a reasonable cost. LASer-welded corrugated-CORe (LASCOR) metallic sandwich panels are stiff, lightweight steel structures that offer the Navy corrosion resistance, reduced weight and less distortion. The objective of this Navy Metalworking Center (NMC) project is to complete tasks needed to support the transition of LASCOR use to future Navy applications. This is being accomplished by optimizing the LASCOR design for materials, manufacturability, joining, structural and protection performance and cost.


Process Improvement:
This ManTech project has demonstrated the capability to manufacture large (78 x 240-inch) LASCOR panels using CRES 2003, a lean duplex stainless steel from Allegheny Ludlum. Corrosion, material and large-scale structural testing have shown that these stainless steel LASCOR panels provide enhanced strength, protection and corrosion resistance. Potential LASCOR applications being investigated for implementation include decks, bulkheads, covers, doors, ramps and other structural applications. Implementation and Technology Transfer:
A competitive bid initiated by General Dynamics Bath Iron Works (BIW) has resulted in a multi-million dollar contract to develop, test and manufacture ship sets of Deck Edge Safety Berms and Personnel Safety Barrier Panels for DDG 1000 using hybrid laser-welding technology, with approximately 84 panels per hull. This technology was selected as the low-cost, technically compliant solution to meet weight, structural, heat and other requirements while offering corrosion resistance, reduced weight and less distortion. Under a joint lead ship program, the first two ships of the DDG 1000 class are being built by BIW and by Northrop Grumman Shipbuilding-Gulf Coast. A separate project is pending endorsement to develop, manufacture, test and subsequently qualify LASCOR trough cover panels for integration into the Electromagnetic Aircraft Launch System (EMALS) test program as the baseline design for the CVN 78. Nearly 700 panels are required per hull.

Expected Benefits:

  • Implementing the use of laser-welded metallic sandwich panel technology for the DDG 1000 Deck Edge Safety Berms and Personnel Safety Barrier Panels offered a sound technical solution for the lowest price while increasing competition.
  • Successful implementation of an alternate corrosion-resistant metallic sandwich panel design concept for the EMALS trough cover application could potentially reduce weight while significantly reducing acquisition costs


  • PEO Aircraft Carriers
  • Naval Surface Warfare Center Carderock Division
  • Naval Sea Systems Command
  • Northrop Grumman Shipbuilding-Newport News
  • Navy Metalworking Center
  • Applied Thermal Sciences
  • Institute for Manufacturing and Sustainment Technologies
  • Daniel L. Winterscheidt
    NMC Program Director


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