The U.S. Navy has been using aluminum to help build ships for more than 100 years and continues
to rely on aluminum almost exclusively for the fastest and lightest ships in its fleet, including
Littoral Combat Ships, Joint High Speed Vessels and future Ship to Shore connectors. All of these
ships use aluminum alloys as a primary structural material.
Aluminum has been widely used by most marine countries for “… the U.S. Navy
commercial and naval vessels since the mid 1950s, and should consider
numerous current U.S. Navy ship classes use substantial aluminum ships
amounts of aluminum. However, long-standing misperceptions
for a broader range
about aluminum ships continue to persist, even though
continuous progress and technology advancements have of roles, not just
mitigated many of the past problems with aluminum. high speed
operations.”
This paper explains how new technologies and advancements
are making aluminum an increasing popular choice for military “The Benefits and Cost Impact of
ships of all sizes and discusses how historical concerns about Aluminum Naval Ship Structure”
Aluminum Welders: There are more skilled aluminum welders than there are active members of
the U.S. Navy and U.S. Coast Guard combined. That means there are nearly 50,000 skilled
aluminum welders in the United States and more than 300,000 aluminum welders worldwide.
One of the advantages of aluminum ships is that only the underside of the ship needs painting.
Unlike steel, the inside of the structure can be left unpainted. It will react with air to form
aluminum oxide—a hard, protective coating that protects the underlying aluminum. With the
thousands of naval craft in service around the world, significant corrosion problems are the
exception not the rule.
Burning & Fire Retardance: Some critics believe that aluminum will burn, thereby making it a
less desirable material for military ships. But aluminum as used in marine structural applications
does not burn and is not toxic. According to a Department of Navy report, media-reports of
aluminum ship damage “in every case was caused by either fuel fires or massive explosions, and in
some instances included ships with steel superstructures improperly reported as aluminum.”1
1Department of the Navy Report on Aluminum Ship Structures to the House Appropriations Committee --
Defense, 1996
Aluminum is a tough material that has proven to hold up well in naval ships. When the Japanese
Coast Guard retired the Arakaze patrol ship 1981, it took samples from various parts of the ship to
test for fatigue and corrosion. The aluminum was still in good condition after 27 years of service.
And that ship was built in 1954, before advancements that further improved the endurance and
survivability of aluminum ships.
Availability of Marine Grade Aluminum: Marine grade aluminum – including sheets, plates,
extrusions, forgings and castings –are readily available from aluminum mills or distributors in the
United States and around the world. The American Bureau of Shipping currently lists 23 approved
suppliers of aluminum flat rolled products and extrusions.
Cost: The acquisition costs of aluminum ships are competitive with steel ships. The material costs
of building a ship are only 1-2% of the total cost of the ship. Major costs are associated with the
manufacturing of the ship. Today’s advancements in manufacturing with aluminum, are offering
significant cost savings, and making aluminum ships in parity with steel ships. Shipbuilders such
as Austal are implementing additional improvements in the production of aluminum ships –
involving router cutting, work kitting, complex extrusions and welding – that will significantly
improve productivity and reduce costs in the future because labor is the highest cost in building a
Aluminum ships have a clear advantage over steel ships in total ownership costs. That’s because
aluminum ships are lighter and use less fuel than steel ships. Aluminum ships also do not incur
lifecycle maintenance costs associated with painting, and because they are generally smaller, they
require less manning. And when an aluminum vessel reaches the end of its life span, it continues to
provide tremendous value as a result of its high recycling value.
While there may have been a time when legitimate concerns existed
about the use of aluminum in naval ships, those concerns have largely
been eliminated through technology advancements. Aluminum has
proven itself as a lightweight, durable and affordable material that allows
naval ships to travel faster and farther.
Aluminum is a proven structural material for marine applications. The attributes of aluminum can
help the Navy achieve its modern fleet needs.