Statement of work (SOW): task title: full scale leak rate characterization tests of the NASA engineering and safety centers composite crew module. 1.0 introduction/background: the NASA engineering and…

Statement of work (SOW): task title: full scale leak rate characterization tests of the NASA engineering and safety centers composite crew module. 1.0 introduction/background: the NASA engineering and safety center (nesc) composite crew module (CCM) project was a technology demonstration task to design, develop, manufacture, and test a full scale composite crew module primary structure based on the constraints associated with the orion element of the NASA constellation program. Since the nesc composite crew module project was performed on a schedule that was accelerated from the orion project, loads and interfaces were incorporated and frozen in june 2007. Thus some of the loads and interfaces on CCM today are not consistent with todays version of the orion crew module. During the design phase of the CCM project, the orion project office expressed concerns with the nesc rationale for managing leakage through the composite material system. At that time, the technical solution was to use autoclave cured sandwich skins with UN-vented core, providing two unique barriers to leakage through the sandwich system. There were concerns identified with that rationale in that undetectable damage could cause micro-cracking of the laminate in the skins, resulting in a compromised first layer. Coincident damage on the second layer would result in an undetectable leak path. Given the significant number of attachments on both the interior and exterior of the crew module structure, the possibility of undetected damage is present, and therefore the leak management rationale as originally proposed was not accepted. During the manufacturing phase of the CCM, a highly flexible membrane was identified that could be installed on the interior of the CCM using a pressure sensitive adhesive. This membrane has a capacity for large elongation so that IT can be stretched over irregular shapes, such as bolts, as well as conform to ODD shapes and surfaces. The membrane film was also shown to be damage tolerant through impact testing that resulted in a cracked laminate skin while the film was unaffected. This film/laminate skin was evaluated in a permeability test fixture both with and without damage and indicates a possible solution to a damage tolerance leak prevention membrane. For the purposes of this statement of work, this film/laminate skin/membrane will be identified and called a liner in these test procedures. 2.0 scope / objective(s): the scope of this task order is to characterize the leak rate through the composite shell system of the nesc composite crew module in its as manufactured state and with a post manufacture installed leak prevention membrane, hereafter called a liner. Permeability testing of composite material coupons is also included as part of the understanding of the composite materials used in the CCM. The objective(s) of this task order are to 1. Develop a test method for characterizing the permeability of selected composite material coupons; 2. Perform and report results of permeability testing of the composite material coupons with and without damage and with and without an applied membrane film; and 3. Perform and report test results of leak testing of the composite crew module (CCM) in eight (8) different configurations in the marshall space flight center (msfc) vacuum chamber V20. 3.0 description of the work/tasks to be performed: the contractor shall serve as the test conductor for all tests described in tasks 3.1 and 3.2. Marshall space flight center (msfc) personnel or existing on-site NASA contractor personnel, will provide facility support including operation of the msfc V20 vacuum chamber, support equipment, overhead cranes, forklifts, and other necessary equipment. The contractor shall perform the following tasks: 3.1 composite coupon characterization tests 3.1.1 the contractor shall develop the characterization test method and discuss method during a