Within the project has been developed a material believed capable of withstanding the high temperature, high reactivity, high force, and severely abrasive environment that characterises the friction stir welding (FSW) of steel.

Samples of the material have been formed into tools of three different baseline designs for FSW of steel and delivered to TWI (The Welding Institute) for evaluation.

The physical delivery of these baseline tools to TWI for testing represents the fulfilment of deliverable D1.1 of project RESURGAM, stated as: D1.1 Baseline puck and tools for welding steel from 2 to 6mm thick.

Element Six has developed a material believed capable of withstanding the high temperature, high reactivity, high force, and severely abrasive environment that characterise the friction stir welding (FSW) of steel. Samples of the material have been formed into tools of three different baseline designs for FSW of 6mm steel (Deliverable 1.1) and delivered to The Welding Institute (TWI) for evaluation.

A second series of tools have now been generated, based upon that initial work, but now designed for welding steel from 8 to 12mm thick. The physical delivery of this series of 12mm tools to TWI for testing represents the fulfilment of deliverable D1.2 of project RESURGAM, stated as: D1.2 Baseline puck and tools for welding steel from 8 to 12 mm thick.

Element Six has developed a material believed capable of withstanding the high temperature, high reactivity, high force, and severely abrasive environment that characterise the friction stir welding (FSW) of steel. A second series of tools were generated, based upon that initial work, but now designed for welding steel from 8 to 12mm thick. The physical delivery of this series of 12mm tools to TWI for testing represented the fulfilment of deliverable D1.2 of project RESURGAM, stated as: D1.2 Baseline puck and tools for welding steel from 8 to 12 mm thick.

From this point the work continued in this task to achieve the D1.3: Preliminary Friction Stir Welding machine specification for carbon steels in air, developed by TWI. This report contains a preliminary FSW machine specification for two friction stir welding machines:

1. One capable of performing an underwater patch repair in steel up to 12mm thick, this machine being developed under the leadership of Forth Engineering in Work Package 3;
2. A second FSW system capable of being retrofitted to an existing CNC machine to perform FSW in air for the manufacture of ship sub assemblies such as stiffened panels.This FSW system is being developed under the leadership of Stirweld in WP4.

The report outlines the basic principles of friction stir welding and the particular considerations that need to be made when the process, originally developed for aluminium, is transferred to welding steel. These specifications are based upon the early stage output from Work Package 1, and before the welding process parameters have been optimised, either for maximising the welds’ properties or for minimising the requirements placed on the FSW machine.

Also during this first 12 months the work to achieve the D 1.4 ( Report on baseline tool reliability, repeatability and longevity) started.

The report focuses on the performance of the baseline tools, primarily their longevity and consistency, and not on the properties of the welds themselves. Weld quality will be reported separately and in detail: all that was required for the purpose of this deliverable was that the welds made by the tools were consistent and fit for purpose

This task began at month 7, acordingaccording with schedule. The welds produced by TWI were analysed by TUD. A range of mechanical tests were performed to generate data on the strength, hardness, toughness and fatigue properties of the joints made. These data were correlated with the weld macro and microstructures, along with the tool designs and weld process parameters used to make the welds. This generated a body of knowledge on the process: property relationships that will guide future tool improvements and form the basis of the working parameters that the shipbuilding and repair industries will require in order to adopt the technology.

This task will run until the end of the project, its first major milestone is the achievement in month 18 of the D 1.5 (Initial report on mechanical properties of FSW welds in steel).

The submission of this deliverable represents the achievement of the first relevant Milestone for the project: MS1: FSW weld property assessment to validate application suitability. The lead beneficiary is TWI. The mean of verification is the D1.5 completed; on-track to apply process parameters to other WPs.

Within task 1.2, during the first 12 months of the project, deliverables D1.2 and D1.3 were executed, which served as a starting point for the elaboration of deliverable D 1.4( Report on baseline tool reliability, repeatability and longevity), completed in month 16. The work continued with a view to the preparation of D1.6, completed in month 24, thus completing Task 1.2 “FSW process development”.

The Deliverable 1.6 “Friction stir welding process parameters for shipbuilding steels” comprises data on the welding parameter envelope investigated for the two specific friction stir welding tool sizes developed for the project by consortium partner Element Six. This report builds upon D1.3 and D1.4 which respectively outlined the requirements of the friction stir welding process in terms of a suitable welding machine and an appropriate welding tool.

This report constitutes Deliverable D1.6 of the RESURGAM project, a report on “Friction stir welding parameters for shipbuilding steels”. It thus comprises data on the welding parameter envelope investigated for the two specific friction stir welding tool sizes, 6mm and 12mm, developed for the project by consortium partner Element Six. The report presents the welding parameters investigated and their effects on:

1. The tool;
2. The forces and torque generated by the process and experienced by the FSW machine;
3. The baseline quality of the welds made

Viable parameters were generated for producing good welds in carbon steel up to 12 mm thick, and these were shown to produce welds both in air and under water. The process parameter envelope for the two specified thickness of carbon steel, 6mm and 12mm, was extensively investigated in air, and selectively for under water welding to confirm the parameters were valid in this environment.

The report summarises the work done to develop the RESURGAM GUI digital platform (Mock-Up) which will connect the European shipbuilding and ship maintenance supply chain and value chain and provide them with digital design and simulation tools to allow remote collaboration.

The GUI Mock-up has been built using the Balsamiq Wireframes. It is a web-based application. The advantages of setting up as a web-based application are:

1. Very user-friendly and intuitive.
2. Various tabs and features are self-explanatory.
3. It is also easy to amend, add or remove tabs as the project grows.

This is a work in progress, and a number of other features will be integrated or implemented as the project progresses.

The work done in D2.1 (GUI Platform Mock-up) was the basis to continue the Task 2.6 (Development of RESURGAM digital platform) according to the calendar, the D 2.2 was developed in due course. The report summarises the features of a fully functional RESURGAM Digital Platform (RDP) which will connect the European shipbuilding and ship maintenance supply chain and value chain. Currently, this is an alpha version of the RDP, where previously identified user roles has been integrated. In the design of RDP, within the Resurgam project have been taken necessary steps so that it remains compliant with relevant regulations.

Within this WP2 also in this 12 first months was also developed the D2.3 Report on how proposed design meets GDPR and other relevant regulations. This document identifies the relevant standards and frameworks that are necessary for the Resurgam Digital Platform (RDP) to operate successfully. One of the most important frameworks identified is the General Data Protection Regulation (GDPR). RDP is not primarily designed to collect personal information from individuals, however an in depth assessment suggest that some functionality of RDP may involve personal data, as a result, either currently or in the future need to be abided by the identified legal framework. The document then discusses all the steps that are taken to ensure the functionalities of RDP remain in compliant with the framework. Some of the important steps include, providing privacy notice to individuals, compliant with the principle of GDPR, a lawful basis for processing (i.e.consent), ensuring adequate security, documenting processing activities and providing individual right. The document also includes a sample privacy notice with the relevant contact details.

This deliverable identifies the relevant standards and frameworks that are necessary for the Resurgam Digital Platform (RDP) to operate successfully. One of the most important frameworks identified is the General Data Protection Regulation (GDPR). RDP is not primarily designed to collect personal information from individuals, however an in depth assessment suggest that some functionality of RDP may involve personal data, as a result, either currently or in the future need to be abided by the identified legal framework.

The deliverable then discusses all the steps that are taken to ensure the functionalities of RDP remain in compliant with the framework. Some of the important steps include, providing privacy notice to individuals, compliant with the principle of GDPR, a lawful basis for processing (i.e.consent), ensuring adequate security, documenting processing activities and providing individual right. The document also includes a sample privacy notice with the relevant contact details..

The task ended with the completion in month 19 of deliverable D2.4. “RESURGAM digital platform alpha version report”. The report explains in detail all the tool developed and integrated in RDP. Most of the tool were identified in the first 6 month of the project by conducting user interviews. However, there are somo tools which were recently identified as useful and therefore is developed and integrated in RDP.

Currently, RDP is in the testing phase, upon success in this phase, RDP will be promoted to the Beta version. From the Beta version the Resurgam project will start to develop and integrate the training tool.

Within this task the newly developed algorithms will be tested and validated in several stages start-ing from computer simulation, physical tests in isolation, integration in a computer simulation envi-ronment and, ultimately, real physical tests. End-users will be involved from the early stages of the process (co-creation) and the ultimate results and improvements achieved will be evaluated against their requirements. Benchmark and real data will be used in this evaluation process.

The deliverable D2.5 “FSW Quality Control of AI/ML Tools”, summarises the work performed in task1-5 of the work package 2 of RESURGAM project. The work presents an approach by which users can control the quality of the weld in the welding process. The development on this work started by defining the real-time Acoustic Emission (AE) data acquisition settings and signal features. Following this a test methodology was adopted that would results in different type of damages in the weld and on how the corresponding AE data will be collected.

After that extensive data analytic technique was em-ployed to determine whether AE technique was sensitive enough to identify damages in the weld-ing process. Finally, Machine Learning (ML) tool was used to automate the damage detection pro-cess. The outcome of the ML algorithm provides feedback on the quality of the weld to the users, this allows the users to act upon to stir the quality to the desired standard.

---

At this point in the project, month 24, one of the milestones of the project is reached, specifically the one set for WP2 (I 4.0 Backbone). Future steps will be at M32 with the Digital Platform User Manual.

In this deliverable Forth have produced an option paper for both the Modular Mechanical Frame and Clamping System.

These are vital in defining the process by which the end goal of the project is met. These have been combined into one document and are being reviewed by members of Work package 3. Forth have also secured the steel for the mock ships hulls and have already manufactured a mock hull for magnet trials which took place at the end of July 2021. Further to this Forth have worked alongside TWI on the spindle options and drawn up an interactive version of the high-level GUI control interface.

The creation of these optioneering papers, trails and control actions represents the fulfilment of deliverable D3.1 of project RESURGAM, stated as: D3.1 Report on process definition and technology selection.

This task started in M6 of the project and concluded with deliverable D.3.2 in M18. Several meetings were held to discuss camera/ lighting to be used on UOL working class ROV, or also to discuss Acoustic Emissions system test on FSW in the lab. Deliverable 3.2 (Underwater repair protocol): To enable the robot to be deployed, and repairs made, it will be necessary to know and understand the location of the damaged vessel, the type and degree of damage sustained, the accessibility of the damage and the structural design of the ship in the damaged area in order to allow a repair to be planned and executed..

The activity of this task began in M10. Several meetings were held, for instance, to update programme to add in review checklist on the control system and, also to Expand communication control design package within the programme. M18 has been a significant date as Deliverable 3.3 has been completed. D 3.3 (Underwater repair protocol) will develop the required protocols for data exchange and ensure they are useful to the repairers, designers and classification societies. The partners have the expertise in the development and use of such data to assess the ship´s condition and design the repair process.

At the conclusion of this task, which will be in month 24 with deliverable D 3.4., it´s expected that The FSW head and its supporting systems will be capable of being deployed to gather the initial survey data and communicating this to the repairers and classification societies, and then being deployed to perform the repair itself. Forth will undertake the production of the system aided by all the other partners. .

 At the conclusion of this task, in month 24 with deliverable D 3.4. “Prototype system for underwa-ter inspection/monitoring and FSW”, as expected, the FSW head and its supporting systems are capable of being deployed to gather the initial survey data and communicating this to the repairers and classification societies, and then being deployed to perform the repair itself.

Forth will under-take the production of the system aided by all the other partners.

Also at this point in the project, month 24, other important milestone has been reached. In this case, the activity of work package 3 is finished.

After completion of D3.2 in M18, this task was finally completed in month 24, with the completion of deliverable D3.5. Prototype system for underwater inspection/monitoring and FSW.

The design check report for the weld head, magnet trials for the FSW capability to be enabled is described in detail.

The D4.1 Report on Suitable Components for Modular Assembly is focused on presenting various examples of steel made ship and offshore sections/structures of modular type (e.g., stiffened panels) along with required grades and thickness of steel to which the FSW technology could be applied as a cheaper and more ecological alternative to the classical welding methods, as well as how friction stir welding could potentially help European shipyards to improve their production rate and in their com-petitiveness in global market.

Using outputs from task D4.1 Report on Suitable Components for Modular Assembly, a survey has been undertaken to establish the range of CNC type ma-chines currently available for shipbuilding fabrication and the proportion of those that could be adapted to undertake FSW.

Prototype FSW head for steel modular outfitting.

Task 4.3 continued in the last 6 months of the project, with the goal of achieving the required data exchange infrastructure to facilitate the creation of a secure supply chain. D 4.4. Data Exchange/ Infrastructure Protocol, the deliverable associated with this task, meant the end of this activity.

J4IC will brought together the Industry 4.0 elements and ensured that the required protocols for data exchange on the communications backbone were completed and fully functional. Data was securely exchanged between those requiring it and shown to be secure, traceable and available in the required formats specified by each en user.

This activity was developed between month 24 and 30 of the project. In month 36 deliverable Deliverable 5.1 (I4.0 Infraestructure Integration) was completed.

The required subsystems for the robotic under water FSW were assembled and tested by Forth and Uol since month 25, when the task began.

The system was demonstrated in Forth´s Deep Test Pool, where it surveyed a representative hull structure placed in the Deep Test Pool, generating survey data that was be provided to NED across the representative I4.0 infraestructure provided in Task 5.1. This survey data was assessed by NED and a repair strategy and a appropriate repair patch devised. The patch was welded in place by the robot, the weld non-destructively tested and the repair fully surveyed. These survey data was transmetted to NED for assesment and a case drawn up for provision to a classification society in order that the repair can be qualified.

This activity started in month 25 and was developed until the end of the project (month 36), when deliverable D5.2 (RESURGAM Robotic System Performance Report) was delivered.

A stiffened panel, was be designed and specified by NED. The specification passed across the I4.0 infrastructure to a yard within ACLUNAGA cluster.

The FSW head developed by STIRWELD will be integrated onto a CNC machine and used to weld the specified component. Then was scanned and measured with the results of this survey being transmitted back to NED across the I4.0 infrastructure delivered in Task 5.1.

The results of the scan was compared with the digital twin and a case drawn up for submission to a classification society to qualify the module as being fit for purpose. This activity started in month 25 and was developed until the end of the project (month 36), when deliverable D5.3 (RESURGAM modular fabrication capability performance report) was delivered.

This deliverable report, D6.1 includes the initial Dissemination & Communication (DC) Strategy and Plan to be implemented during the RESURGAM project. It covers all the planned aspects regarding communication and dissemination and the associated target groups & stakeholders to be involved. Additionally, the communication measures to be put in place for each of the foreseen activities are also described, including the tools to be used and an indicative place and time to organise them.

Dissemination and Communication activities are a fundamental point in RESURGAM project. The developed project outputs must be continuously disseminated during the duration of the project. These two activities groups are crucial to ensure the sustainability of project results over time. Such activities are considered a backbone for the project success and will help the long-term viability of the project outcomes.

This Deliverable is part of the WP 6 – Dissemination, Communication and Exploitation of Results which is led by EWF (with involvement of all partners). This Deliverable was already elaborated is considered a living document to be constantly updated during the life of the project, something that has also been done for this period.

D6.1 Dissemination & Communication (DC) Strategy and Plan

The Deliverable 6.2 Dissemination Report & Marketing Plan has been under development since the beginning of the project. report measures and evaluates the dissemination and communication activity developed for the duration of the project by each of the project partners. This was the starting point for the following reports that were developed every six months, and that was devel-oped by ACLUNAGA, as Dissemination, Exploitation and Communication Manager. Besides being collected annually in the activity 6.2 (Report on Dissemination/ Communication activities & market-ing plan) by the WP leader, based on the Dissemination Tracking Document (ANNEX I of the Com-munication Plan - Activity 6.2- WP 6). To manage the performance of dissemination and communi-cation activities, several indicators have been identified. These were measured continuously, re-flected in the Project's SharePoint, to ensure a continuous growth of RESURGAM's visibility.

The dissemination material was adapted as needed to suit the target audience during the project.

The project website provided updated information to RESURGAM stakeholders about the projects and its activities, as well as features for enquiries and technical support. A section of the RESUR-GAM website and digital platform containing promotional material was created and updated regu-larly with news including new and blogs relating the project and its outputs. D6.2 Dissemination Report & Marketing Plan

An exploitation plan was developed within this task to a formalized business proposal for post-project development/commercialisation and investment needs, creating detailed business plans and com-pelling investment cases to present to both investment institutions, individuals (business angels) and follow-on public-private funded initiatives (e.g. Horizon Europe). Thus, the D6.3 Exploitation and Sustainability Plan was developed to gather inputs from the consortium partner to assure that the RESURGAM project results are assessed to be exploited.

This document aims to align all partners regarding the exploitation of the project’s outcomes and assure that every partner is aware of their role in the value chain of the final results.

Furthermore, in order to assure that the project’s developments are taking the right steps towards the expected outcomes of the project, a set of individual technical and non-technical, Key Perfor-mance Indicators – KPIs, from each partner, were collected. This provided a valuable information to guide the developments of the project and determine what each partner is expecting to take out of their involvement in the project.

D6.4 (RESURGAM Innovation Community): is a Report about initial RESURGAM Collaborative Production, Maintenance and Innovation Com-munity, it will be ready in month 36, the end of the project.

The consortium elaborated a detailed and diversified exploitation plan that took all background IPR owned by consortium members into consideration to ensure effective exploitation of the project’s results. This involved exploring and implementing suitable methods to protect different project results: applying for patents, design rights or copyright as and when appropriate.

RESURGAM ro-botic UFSW system, modular fabrication/maintenance FSW capability and digital platform reach TRL6 by the end of the project. In this task, with the advice and support of the commercial advisory board, Resurgam project developed a exploitation plan. The expected impact of the RESURGAM project was followed up closely. From the beginning of the project, specific attention was given to the protection and exploitation of foreground IPR resulting from the project. IPR ownership and exploitation agreements was created in the form of potential license agreements, described in the plan for dissemination and exploitation of results and the detailed in our Consortium Agreement.

D 6.5 (IPR Report) was prepared with all the information and work developed in task 6.4.

A sound quality assurance framework allows for a flexible and efficient adaptation of any project to any potential difficulties or changes in its initial scope. To that end, the following report outlines a quality assurance plan (QAP) for the RESURGAM project.

This QAP gives an overview of the project structure, roles and responsibilities that will play a part in the implementation of the strategy, as well as the components in place to ensure that progress is neatly reported on, through the project’s planned Deliverables and Milestones. This document outlines RESURGAM’s approach towards ensuring quality of the project outcomes, particularly the project deliverables and expected publications and handling of data, by the consortium.

The document is split into two distinct elements:

1. Outline of the pathways ensuring the common approach to validating the preparation and submission of preparation of project deliverables;
2. A data management section, including individual data management forms, detailing the different types of data and how they are processed, across the individual partners.

The consortium recognizes that these are crucial components for a successful project and will revisit the plan to incorporate changes and shifts in the project planning, especially in terms of the data man-agement and control. These revisions will take place in parallel to the preparation of the commission’s periodic reports.

Project Management tools and methodologies are instrumental for the successful implementation of any research and collaborative project. The RESURGAM consortium acknowledges this and has endeavoured to set up a robust project management structure to ensure that the implementation (both technical and administrative) of the project is carried out seamlessly.

The D7.2 Project Management Plan intends to assist both the Project Coordinator and the Technical Coordinator in tracking the major project tasks, deliverables and milestones.