The U.S. Navy is planning to replace traditional welding with electron beam welding on its Virginia Class Submarines to reduce manufacturing costs and improve the quality of the welds.

The Naval Metalworking Center said it intends to use electron beam welding in the fabrication of first reduction gears on the Virginia Class Submarine as part of a project for the Office of Naval Research.

The Naval Metalworking Center is working with the Virginia Class Submarine Program Office, the Naval Sea Systems Command and Northrop Grumman Electronic Systems- Marine Systems to carry out the project.

In a statement on the project, the Naval Metalworking Center said current welding processes used to make the first reduction gear on the Virginia Class Submarines require multiple passes in complex sequencing, and some joints require double-sided welding to ensure full penetration.

The 14-month project is expected to reduce costs by incorporating single-pass, full-penetration welds; use narrow welds that improve fit-up and simplify machining operations on fabricated gears by reducing rim-to-shaft distortion; eliminate the need for closing plates on gear fabrication; and reduce Magnetic Particle Testing requirements due to single-sided welds that are associated with the manufacturing process as well as improve the quality of the welds and reduce fabrication time.

Separately, the Navy Metalworking Center published a technical bulletin on laser-welded metallic sandwich panels that are expected to reduce weight to improve combat effectiveness and maneuverability of ships while remaining affordable.