The choice of methods for manufacturing hull structures of ships from polymer composite materials

This paper discusses the application of polymer composite processing technologies in the manufacture of hull structures of displacement vessels, describes the main components used, and reviews the primary manufacturing methods approved for use by the Russian Maritime Register of Shipping. The selection of a specific method depends on multiple factors, and in certain cases, shipyards are compelled to deviate from the classification society’s recommendation to apply the resin infusion method as the main process. Technological procedures employing the contact molding method are analyzed. For the particular case of producing the outer hull plating of a displacement vessel, justification is provided for selecting a method other than the recommended one. With an identical reinforcement scheme, the side plating thickness obtained by the infusion method was, as expected, lower than that produced by contact molding; however, the contact molding method ensured compliance with the design thickness. Applying the infusion method required the addition of extra reinforcement layers, increasing cost, production time, and structural weight. At the same time, tensile strength and stiffness characteristics of the infusion-produced samples exceeded those of the contact-molded ones. The contact molding method proved more cost-effective, primarily due to lower material consumption, the use of less-skilled labor, and the absence of high production risks. It is proposed to adopt the infusion method as a baseline for calculating hull plating thickness, which could serve as one of the approaches to incorporating the manufacturing method into the structural design process. Addressing the challenges in this field will facilitate the industrial implementation of advanced composite manufacturing technologies based on resin infusion.

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