004. Draft PWS - 80MSFC25DA001.pdf

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ATTACHMENT J-1

STATEMENT OF WORK

STATEMENT OF WORK (SOW)

TESTING AND ANALYSIS OF PROPULSION SYSTEM MATERIALS & SPACE

SYSTEM MATERIALS FOR MSFC

1.0 GENERAL

The Contractor shall furnish the necessary management, personnel, equipment and materials, not otherwise furnished by the Government to provide testing and analysis for materials of interest to Marshall Space Flight Center (MSFC). In support of NASA-led activities (including support for NASA activities and other reimbursable work for which MSFC has responsibility including in support of Department of Defense (DOD), other Government, commercial, or educational activities). The testing and analysis effort to be performed by the Contractor is broadly defined in this PWS and will be specifically described in task orders authorizing the performance of this effort. The MSFC Materials and Processes Laboratory (M&P) will use the data to investigate material constituent variation, process variable and environmental effects on the thermal, physical, and mechanical properties and performance of these materials. The Contractor shall provide characterization test plan definition, material property determination, data evaluation and engineering analyses, nondestructive evaluation, environmental conditioning, failure mode determination, microstructure evaluation, and process development and assessment. The primary use for much of the data to be generated under this PWS will be materials properties data input for thermostructural analytical models. As such, laboratory test data for any part of this work, when requested by MSFC, shall be submitted by the Contractor in a computer media with format compatible with state-of-the art analytical codes and material properties databases.

2.0 TESTING AND ANALYSIS

All tests and analyses shall be conducted according to industry standard procedures where they exist or unique procedures with respect to test pedigree simulation goals, both of which shall be approved by the Government prior to use. This PWS is not limited to the state-of-the art testing techniques and capabilities listed below. Additional testing techniques may be substituted as the technology expands to provide improved understanding and predictive capability for material response and performance, at the request of and/or with the approval of the Government. These properties shall be measured under conditions designed to simulate the conditions in application including temperatures up to 6000°F, oxidizing environments up to temperatures in excess of 4000°F, and cryogenic temperatures as low as -450°F at a minimum. For any flight related testing, the Contractor shall comply with the quality provisions specified in attachment J-3.

2.1 NONDESTRUCTIVE EVALUATION

Utilization of various techniques will be required for (1) mapping of anomalous areas, (2) assessment of test material uniformity, (3) verification of ply alignment, (4) identification of

J-1-2 defects for determination of subsequent effects on material properties, and (5) characterization of density variation in materials mentioned in Section 1.0A. The Contractor shall have the capability to conduct ultrasonics, ultrasonic spectroscopy, collimated radiography, computed tomography, and eddy current at a minimum. They shall be applied as appropriate for the particular material system or component and type of defect to be assessed.

2.2 ENVIRONMENTAL CONDITIONING AND SAMPLE AND TEST PREPARATION

In an effort to closely match the application unique space transportation environments and loads, standard tests are typically not available. Specimen design, coupled with appropriate test hardware, is critical in achieving accurate property or behavior of the test specimen. Therefore, the Contractor shall have the capability to prepare specimens, design unique test hardware and specimens, fabricate hardware test fixtures, and generate test procedures to achieve the most accurate data possible.

Test matrices shall be developed for each task with input from the Government.

Recommendations for data requirements shall be sought from experts in thermostructural analysis for material of interest as appropriate.

The Contractor shall have the capability to determine the relationship among material permeability as a function of temperature, volatile content as measured using standard tag end acceptance methods, and total volatile/moisture level and the effects of these variables on the critical properties of composite materials. The properties are necessary to provide input data to thermostructural analyses for verification of component structural integrity, safety margin predictions, and reliability assessment. Evaluation of the conditions encountered between fabrication and launch will be required to establish realistic and worst case conditions. The contractor shall have the necessary equipment to adequately dry and moisture condition the test materials at various temperatures and humidity levels, and the equipment needed to perform volatile off-gas analysis.

As it may prove desirable to prevent or reduce the deleterious effects of service life environments, including moisture diffusion into materials, the investigation of environmentally resistant coatings may be required. The Contractor shall have the capability to survey available coating materials, determine the effectiveness of; the coating to prevent degradation or retard moisture diffusion over short and long terms, application methodology, and coating pedigree on performance.

A determination among the relationship between oxidized and non-oxidized ceramic and ceramic composite materials will be required. The contractor shall have capability to conduct material heat treatments and tensile and compressive testing in oxidizing atmospheres from ambient to 10-2 Torr or lower pressures while at temperatures that range from -270 C (-450 F) to 4000 C (7232 F) at least.

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2.3 ALIGNMENT, ACCURACY, AND RESOLUTION

Testing of high temperature and strain sensitive materials requires precision alignment.

Alignment on all testing shall be appropriate for the nature of the material being tested such that the parasitic stresses do not adversely affect the property being measured.

Testing accuracy (e.g., getting highest pure tensile strength and not influenced by bending loads or off-axis stress fields due to inaccurate alignment or specimen design respectively) shall be less than 5% parasitics for brittle materials. Instrumentation accuracy and resolution shall be appropriate for data of interest sought.

2.4 MATERIAL CHARACTERIZATION

The Contractor shall have the capability to conduct extensive characterization of the test materials through determination of physical, mechanical, and thermal properties. The properties determined shall include; standard properties used in thermostructural analyses (i.e., tensile, shear, compressive strength and modulus, thermal expansion coefficient, thermal conductivity, specific heat, and Poisson’s ratio, at a minimum); constitutive relationships (i.e., prepreg or preceramic polymer type, preform architecture pedigree, fiber and material coatings, fiber type and treatment, composition, resin and filler contents, volatile content, and resin advancement at a minimum); and those specially developed diagnostic tests for material integrity assessment (e.g.

restrained thermal growth, off-gas analysis, and permeability, at a minimum). These tests shall be conducted over a broad temperature range encompassing that to which the materials will be exposed during normal operation of a rocket motor. A broad range of loading rates and cyclic loading and fatigue profiles in conjunction with the spectrum of heating rates shall also be required.

Materials characterization shall be required to (a) verify vendor and contractor-supplied data, (b) develop properties on alternate material systems, (c) evaluate existing test methods, (d) develop and qualify new test methods for material acceptance criteria, (e) assess material constituent variations influences and process variable effects on cured part properties, and (f) determine the influence of degree of cure, volatile/moisture level and permeability on properties. Additional testing shall be required to develop a statistically significant database on properties needed for

(a) constitutive material relationships for thermostructural models, (b) high temperature and high heating rate effects, and (c) alternate material system critical properties.

The Contractor shall provide the types of tests listed in Table 1 at a minimum and the minimum temperature range and test capabilities as detailed in Table 1. Instrumentation and data acquisition and data reduction shall be provided for those capabilities to yield the appropriate data understanding and correlations. The contractor shall have the capability to provide measurement and interpretation of material effective porosity. This “property” is critical to the classical thermostructural analyses approach for the prediction of internal pore pressure.

The Contractor shall provide the means to track or catalog and securely store all specimens.

Specimen storage is indefinite, unless recalled by MSFC at any time, and the Government shall not be charged storage fees at the conclusion of this contract. The Contractor shall provide the

J-1-4 means to protect the failure surface after the test. Test procedures, equipment and testing photographs, and specimen design shall be provided for each test.

Table 1. Details on Test Types, Temperature Range, and Test Capabilities

ID Test Type Temperature Range Test unique capabilities Minimum Temp. (°C)

Maximum Temp. (°C)

1 Tension

1.1 Flat specimens (fill, warp) -250 3000

1.1.1 Composite -250 3000

1.1.2 Monolithic -250 3000

1.2 Round specimens -250 3000

1.2.1 Monolithic -250 3000

1.3 Across-Ply -250 3000

1.4 Hoop 20 2300 Full ring tests

1.5 Creep 20 2600

1.6 Fatigue at f>500sec-1

and r=0.1 fatigue 20 1800

1.7 Circumferential

Coupon

-250 2600

1.8 45° (WF) -250 3000

2 Compression

2.1 Flat specimens (fill, warp) -250 3000

2.1.1 Composite -250 3000

2.1.2 Monolithic -250 3000

2.2 Round specimens -250 3000

2.2.1 Monolithic -250 3000

2.3 Across-Ply -250 3000

2.4 Hoop 20 2500 Full ring tests

2.5 Creep 20 2600

2.6 Fatigue at f>500sec-1

and r=-1 fatigue 20 1800

2.7 Circumferential

Coupon

-250 2700

2.8 45° (WF) -250 3000

3 Shear

3.1 Interlaminar

(Warp/Fill) -250 2600

3.1.1 Double Notch -250 2600

3.1.2 Rumanian -250 2600

3.1.3 Torsion -250 2600

3.2 In-Plane

3.2.1 45° Tension -250 3000

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Minimum Temp. (°C)

3.2.2 45° Compression -250 3000

3.2.3 Rumanian -250 2600

3.2.4 Saddle -250 2600

3.2.5 Rail 20 20

3.2.6 torsion -250 2600

3.3 Biaxial 20 20

3.3.1 Tension- Torsion -250 1500

3.3.2 Compression-torsion -250 1500 Provides friction

4 Flexure Strength -250 3000 5 Sonic Modulus -250 1500 6 Coefficient of Thermal

Expansion -250 2600 at parts per billion resolution or greater 7 Thermal Conductivity -250 2600 Multiple techniques for various conductivities

7.1 restrained -250 1000

7.2 unrestrained -250 2600 8 Specific Heat -250 2600 Calorimetry 9 DSC (powders, non-powders) -150 1250

9.1 Heat of Reaction 20 1200

9.2 Temperature on-set of

Heat of Reaction -150 1250

9.3 Glass Transition

Temperature

-150 1250

10 TGA (powders, non-powders)

25 1250 1000F/min or greater heating Rate, Off-gas analysis

11 Thermal Diffusivity 25 1200 12 Density/Porosity

12.1 Bulk Density 20 20

12.2 Helium Pycnometry 20 20

12.3 Mercury Porosimetry 20 20

12.4 Apparent Density 20 20

13 Filament diameter 20 20

14 Permeability (warp, fill, across-ply)

-250 1500

14.1 As a Function of Ten

Strain

20 1000

14.2 As a Function of

Compression

20 1000

15 Karl Fischer VCA 20 20

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Minimum Temp. (°C)

16 Scanning Electron Microscopy

20 20

16.1 EDX Analysis 20 20

17 Optical Microscopy 20 20 18 Emissivity 20 2500 19 Vented Bomb 20 1000

20 DMA 20 1200

21 Diffusion 20 20 22 Analog Testing 20 2200 23 Electrical Resistivity 20 2500 24 Dielectric Properties 20 20 25 Restrained Thermal

Growth 20 1000

26 Poisson’s ratio -250 200

26.1 Composites -250 200

26.2 Monolithic materials -250 200

27 Laser heat flux 20 2700 Through LHMEL

2.5 FAILURE MODE DETERMINATION

Failure analysis is necessary to determine causes of failure and thereby assess the acceptability of experimental data from material coupon tests and component hardware tests. Material failure modes are dependent upon internal defects, material and processing variables, specimen design, and thermostructural test loads. Failure analysis information, including microscopy, shall be utilized in the above areas for (a) correlation of pre-test Nondestructive Evaluation (NDE) for determination of the effects of defects on the test results, and (b) development of failure criteria for use in thermostructural models. Estimates shall be required for likelihood of failure and test capabilities of materials with similar characteristics and processing histories. The Contractor shall identify previous test data of similar characteristics, processing history, and testing.

Component hardware failure analysis shall include identification of material type, process history, and factors contributing to the failure as well as the specific failure mode. Predictions of service operating conditions shall be required for comparison with experimental test conditions and results.

2.6 DATA ANALYSIS AND CORRELATION

Experimental results shall be analyzed and correlations developed in accordance with the objectives of the specific test series. Various detailed areas of investigation in this Performance Work Statement shall require significant post test data analysis to derive trends and identify primary variable effects on mechanical, thermal, and physical properties and microstructural

J-1-7 analysis. Historical property test data shall be used in the failure analysis for Reusable Solid Rocket Motor (RSRM) and Space Launch System (SLS) efforts.

Data shall be organized and presented to demonstrate existing cause-effect relationships and support conclusions. Relevant data within the literature or available from other test programs shall be considered for comparison, as applicable. Upon conclusion of data analysis and correlation, recommendations shall be made for additional testing or materials/fabrication conditions required to address open issues or areas of concern, but only initiated after contract/ task modification.

3.0 PROGRESS REVIEWS, TECHNICAL INTERCHANGES AND PROGRAM PLANNING

The Contractor shall participate in various progress review meetings, technical interchanges, and program planning discussions. The contractor shall serve as the materials properties and testing expert in interchanges and interfaces as approved by the Government. The Contractor shall have the responsibility of interpreting experimental results and of fully understanding the significance of the properties with respect to their use in state-of-the-art thermal, structural, and thermostructural analytical models. This requirement is based upon the fact that frequent interfaces with industry analysts shall be required to enable incorporation of data generated under this Performance Work Statement into analytical codes.

To facilitate program planning and definition of various test matrices, the Contractor shall provide recommendations for test methods, test conditions, and replications required to obtain a particular property, simulate a material event or response, or characterize a material system.

Recommendations for data requirements shall be sought from experts in thermostructural analysis who are knowledgeable in the relevant application area (e.g., both pore pressure code development and of permeability influences on material responses). These recommendations provided by the Contractor are to be substantiated with prior test methods and conditions experience and knowledge of material responses at the expert level. The Contractor shall possess a thorough knowledge of similar or related efforts being conducted for other Government agencies and/or private industry to assist in the development of complementary test programs which would attempt to minimize duplication of effort. This sharing of data has been successfully accomplished under previous programs of this nature among National Aeronautics and Space Administration (NASA), Air Force, and Navy programs benefiting both the Government and numerous private industry organizations through cost reductions. In the present environment of industry and Government-wide budget reductions, this knowledge of related efforts and ability to structure complementary programs is most important.

4.0 REPORTING DATA DELIVERABLES

The Contractor shall report and document the performance of this work in the PWS and fulfill the requirements of the associated Data Requirement Descriptions (DRDs) as outlined in the Data Procurement Document (DPD) 1688 (Attachment J-2). The Contractor shall determine the data restriction that applies to each data deliverable and mark or transmit the data restriction in accordance with section 2.3.3 of the Data Procurement Document.

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The Contractor shall provide test data as it becomes available upon request with appropriate availability marking. A detailed schedule for conduction of different tests and work within a task shall be provided at the initiation of a new task and upon request by the Government during the course of the task (e.g., when samples are delivered for testing, etc.)

The Contractor shall submit a report at the completion of each task order made under this contract with appropriate availability marking in accordance with DRD 1688MA-002. The report shall serve as a self-contained summary including the issue addressed by the testing or objective; full description of the test material; necessary pedigree and fabrication details;

identification of test conducted; discussion of test result(s) and significance; and conclusions and recommendations (as appropriate).

The Contractor shall provide technical information concerning any invention, discovery, improvement, or innovation made by the contractor in the performance of work under this contract. Technology Reports shall be prepared in accordance with DRD 1688CD-001.

The Contractor shall prepare and submit an Environmental Compliance Report in accordance with DRD 1688EE-001.

The Contractor shall prepare and submit an Organizational Conflict of Interest (OCI) Plan in accordance with DRD 1688MA-001.

The Contractor shall prepare and submit a Bi-Monthly Progress Report in accordance with DRD

1688MA-002.

The Contractor shall prepare and submit a Final Task Reports in accordance with DRD

1688MA-003.

The Contractor shall prepare and submit a Financial Management Report (533M) in accordance with DRD 1688MA-004.

The Contractor shall prepare and submit a Final Scientific and Technical Report in accordance with DRD 1688MA-005.

The Contractor shall report mishaps and safety statistics to the MSFC Industrial Safety Office in accordance with DRD 1688SA-001. The Contractor shall submit direct to the NASA Mishap Information System (NMIS) or shall use the forms listed in section 15.4 of DRD 1688SA-001 or electronic equivalent to report mishaps and related information required to produce the safety metrics.

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5.0 QUALITY PROCESS FOR FLIGHT RELATED TEST DATA

During the performance of this contract any flight related test data generated and delivered to MSFC will be required to undergo the following process to determine conformance of quality.

All flight-related test data delivered under this Contract shall require traceability to unique test specimen identifiers, which may include part number, serial number, batch/lot numbers, work authorization number, or other significant identifying information. Specific traceability requirements will be specified in writing by the Contracting Officer Representative (COR) or Delegated Authority and shall be incorporated through the contractor's formal work authorizing documents prior to initiating testing or specimen preparation. As a minimum, the contractor shall provide test reports and certificates of conformance for all flight-related data. Test reports shall list the specifications, including revision numbers or letters, to which the material has been tested and/or inspected, the unique identification and configuration of the test(s) specimens to which it applies, and the actual quantitative test results obtained.

For flight-related test data, Government mandatory inspection points (GMIPs) shall be specified in writing by the COR or Delegated Authority and may be conducted at any stage of testing.

GMIPs will be specified in each individual task order that requires GMIPs. The contractor shall not proceed with any aspect of test specimen preparation or testing until the COR or Delegated Authority verifies that the required GMIPs have been added to contractor's shop planning/work authorization documents. The Government's request for source inspection shall specify the period, the method for the advance notification, and the Government representative to whom it shall be furnished. GMIPs shall not be by- passed unless authorized in writing by the COR or Delegated Authority.

All purchased materials and services are subject to inspection for compliance with this contract and all applicable quality clauses. No material or process substitutions, quantity variations or splits from the contract may be made without prior written authorization from both the COTR and the NASA Quality office.

Work under this contract is subject to government or customer surveillance/inspection at the contractor's plant or sub-tier supplier's facilities. The contractor will be notified if surveillance and/or inspections are to be conducted. No shipments will be held by the contractor for government inspection unless notification is received by the Contractor and is notified by NASA Quality office prior to shipment. (Reference FAR 46)

The contractor shall successfully complete a compliance audit to applicable program/project requirements to be performed by MSFC for delivery of flight verification data and flight hardware.

The contractor shall provide in written advance notification to the COR or Delegated Authority of any changes to tooling, facilities, materials, or processes that could affect test results and/or traceability.

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All applicable requirements that are invoked or applied in these processes, shall be flowed down to the Contractor's sub-tier suppliers.