SOW.pdf

STATEMENT of WORK

PRECISION ENGINEERED INTERNAL PARTS for VALVE INTEGRATED

PRESSURE REDUCER (VIPR) MACHINING 3-D PRINTED MONEL BODIES

I. Purpose and Background

The project is to fabricate machined parts and finish machine 3-D printed Monel 500 bodies for a Valve Integrated Pressure Reducer (VIPR) for use on 5,000psi (with possible enhancement up to 10,000 psi) compressed oxygen cylinders.

NIOSH is developing the VIPR oxygen delivery system (ODS) through an Interagency Agreement (IAA) with the Navy (NSCW-PCD). The ODS is to be used as an integral component of a personal back-worn closed-circuit breathing device for mine escape. The VIPR design uses precision engineered and micro-sized components to be as small and lightweight as possible. The VIPR must be capable of long term storage without significant pressure leakage over time; therefore the design has tight tolerances for these parts to enhanced sealing for leak tightness.

VIPR parts fabrication and finish matching body work is divided into three tasks. Task 1 is the examination and understanding of the VIPR design and drawing package. Task 2 is to fabricate internal machined parts for VIPR reducer and demand valve. Task 3 is the finish machining of the delivered VIPR bodies.

Task 1: VIPR Design

1. Verify that the latest revision of the solid model files/ drawings and specifications of the VIPR design are being used. Updates must be requested from the program office prior to production.

2. Examine the solid model files of the VIPR design and extract the drawings and information of the internal parts of the VIPR reducer and Demand Valve to be fabricated.

3. The VIPR bodies are produced by a third party and will be supplied to the contractor by NIOSH. Examine the VIPR bodies as received and verify that they are within tolerance as 3-D printed parts. Identify the final tolerances and finishes required for each of the two bodies after finish machining.

Task 2: Fabricate internal machined parts for VIPR reducer and demand valve

4. Fabricate 20 sets each of internal parts for VIPR-002-01 and VIPR-A02-X1 reducer designs and 40 sets of internal demand valve parts through a precision machining process using the material specified in the supplied solid model drawing package.

5. Check and verify that the parts produced are within the tolerances required. Compile a report that includes material used, mill certificates and tolerances achieved.

6. Deliver final finished parts to NSWC-PCD for final VIPR reducer and demand valve assembly. The parts should be free of debris, dry and packed appropriately to prevent damage.

SOW – VIPR-ODS parts & finished bodies

Task 3: VIPR Body Finish Machining

7. Post machine the supplied VIPR-002-01 (20 qty.) and VIPR-A02-X1 3-D (20 qty.) 3-

D printed reducer bodies and apply finishing processes to required tolerances.

8. Examine tolerances and finishes of all bodies to design specifications as per the drawings. Compile a report that includes the final dimensions and tolerances achieved.

9. Deliver final finished bodies to NSWC-PCD for final VIPR reducer assembly. The bodies should be free of debris, dry and packed appropriately to prevent damage to the finished surfaces.

No. Deliverables Milestone

1. Report on Internal parts Completion of task 2-5

2. Internal parts for VIPR-002-01 (20 sets), VIPR-A02-X1

(20 sets) reducer designs and 40 sets of demand valve parts Completion of task 2-6

3. Report on the machined bodies Completion of task 3-8

4. Final machined bodies VIPR-002-01 (20 sets), VIPR-A02-

X1 (20 sets) Completion of task 3-9

Project Reviews

• VIPR design review – A design review meeting will be held at the contractor’s site to examine the printed tensile samples, reports, files / drawings and production process & equipment.

Project Support

• NSWC-PCD will provide solid model designs/ drawings of the VIPR and provide design input to contractor.