SATPC0015275_Technical_Specifications.pdf

STATEMENT OF WORK

1. Objective/Requirements The Aircraft Noise Reduction Subproject of the Advanced Air Transport Technology Project has a level 1 milestone of demonstrating 4dB noise reduction from the leading-edge slat of transport-class aircraft in the approach and landing phase of flight. Adaptive structures technology enabled by superelastic shape memory alloy (SMA) materials has been developed to demonstrate this noise reduction on a 10% scale model of a transport-class aircraft. Superelastic SMA materials of a specific alloy composition and heat treatment must be processed to form thin sheet product forms that are shape set by further heat treatment to render structural components of specific shape and dimensions for the airframe application. The SMA structural components will further require specific trim and fastener hole features for fitment with the wind-tunnel model. The specific components that will be the products of this work are termed slat-cove-filler (SCF) and slat-gap-filler (SGF) structures. The SCF structures will consist to two components that will be joined at LaRC during assembly with the wind-tunnel model. The SGF structures are one-piece, but there are two versions that are termed the stress-free-deployed (SFD) and stress-free-retracted (SFR) SGF structures, respectively, where the two versions have differing shape-set geometries.

2. Characteristics, Scope, and Specs

The contractor shall perform the following:

• Work with application requirements input from NASA LaRC researchers to determine the alloy chemistry, processing, heat treatment and shape set parameters to produce components with transformation temperatures that are the best compromise of component producibility and compatibility with test conditions.

• Fabricate shape-set tools for the two-component SCF, SFD SGF and SFR SGF components for the entire wing of the 10% scale, semi-span High-Lift Common Research Model (HL-CRM). The SCF components are restricted to the outboard slat while the SGF components involve the inboard slat, transition slat and outboard slat.

Details on the interrelation of the SCF and SGF components, the number of parts to be fabricated, and a cross-reference of part name to geometry file name are given in the file NASA hl-crm_scf_sgf_sma_parts_list.xlsx.

• Fabricate in triplicate (except as noted for the SFD SGF components, where 6 of each are required) each of the following noise-treatment components. Thickness dimensions for each component and a cross-reference between part name and geometry file name are given in the file NASA hl-crm_scf_sgf_sma_parts_list.xlsx. Thickness dimension of each component shall have an accuracy of ±0.0005 inches or 10%, whichever is smaller. The geometry files available in the distribution folder (AT-HL- CRM_EXPORT_SURFACES_7-29-19.zip) accompanying this SOW consist of a reference surface representation for each SCF or SGF component. In all cases, the reference surface is one of the two outer/wetted surfaces of the component, i.e., not the middle surface. Additional information about the geometry files is contained in supporting_file_description.docx. A graphical representation of the reference surface for each of four component types (SFD SGF, SFR SGF, Main SCF and Reverse Auxiliary SCF) is given in reference_surface_graphics.pptx. The direction for the thickness of the corresponding component type is also indicated. The reference surface representations of the SCF and SGF components correspond to the shape-set configurations only. The shape-set accuracy of each component shall be ±0.005 inches. Solid geometry representation of each SCF and SGF component can be made available upon request.

Geometry files for the corresponding flat configuration for each part, as may be convenient for trimming and fastener hole machining prior to shape set, can also be made available upon request. Component trim and fastener hole locations shall have an accuracy of ±0.005 inches. Spanwise and chordwise dimensions of the parts in the flat product form, i.e., prior to shape-set, shall be within ±0.005 inches of the geometry specifications. Full specifications for the SCF and SGF parts can be found in SMA_PRspecs20190726.docx. Drawings for each component can also be provided upon request. Each part shall be permanently marked, via a mutually agreed format and marking method that will not damage the parts, for identification of the part and its orientation in the model assembly.

o SCF for the outboard slat – The SCF is segmented into 13 spanwise sections. Each of the 13 spanwise sections of SCF structure consists of two pieces: the Main and the Reverse Auxiliary SCF. Each pair is matched in spanwise length and in thickness.

o SFD SGF for the inboard slat – The SGF on the inboard slat is segmented into 4 spanwise sections. The most-inboard section has two versions with a differing side edge at the inboard end, which means two part types exist for that location. The SFD SGF will also be used in conjunction with the SCF. The SFD SGF will be used to treat the inboard slat when the outboard slat is treated with the SCF. Thus, the SFD SGF parts for the IB slat are needed in double the number (6 of each part) to have 3 of each part with each of the two treatment collections: SCF and SGF.

o SFR SGF for the inboard slat – Analogous to the SFD SGF (with 4 spanwise sections), except it will not be used in conjunction with the SCF, so no doubling of the number of parts.

o SFD SGF for the transition slat – One piece that replaces the most-outboard section on the inboard slat and the most-inboard section of the outboard slat and bridges the spanwise distance between the inboard and outboard slats.

o SFR SGF for the transition slat – Analogous to the SFD SGF.

o SFD SGF for the outboard slat – The SGF on the outboard slat is segmented into 8 spanwise sections. The most-inboard section has two versions with a differing side edge at the inboard end, which means two part types exist for that location (each needed in triplicate).

o SFR SGF for the outboard slat – The inner 5 sections are analogous to the SFD SGF. SFD SGF parts will be reused for the most-outboard 3 sections of this assembly on the outboard slat.

• Test material samples from the same material (same processing and shape-set heat treatment) used to fabricate the SCF and SGF components for transformation temperatures and stress-strain response at room temperature for a minimum of one load cycle. Material testing shall be repeated to adequately characterize the material at the different thicknesses used in the component production (see NASA hl-crm_scf_sgf_sma_parts_list.xlsx). A minimum of two tests per material thickness shall be conducted. Test results shall be delivered with the respective components the test results represent. The test results shall demonstrate achievement of the temperature, recoverable strain and strength requirements in SMA_PRspecs20190726.docx.

• Provide a minimum of 3 material samples at each thickness, with the same material processing and shape-set heat treatment that was used for the respective SCF and SGF component, for independent testing.

3. Place of Performance

The material processing, heat treatment, trimming and fastener hole machining, shape setting and materials characterization testing will be conducted by the SMA component provider. Component integration into the wind-tunnel model will be done at NASA LaRC. Additional materials characterization testing may also be done at NASA LaRC.

4. Period of Performance A 4-month delivery/lead time is anticipated and requested with incremental delivery of components over that period.

5. Possible Vendors Johnson Matthey Inc.

Ms. Ramineh Medhat ramineh.medhat@jmusa.com 408-346-4919

FWD Technologies, LLC Mr. Drew Forbes drewjforbes@gmail.com 260-438-7632 mailto:ramineh.medhat@jmusa.com mailto:drewjforbes@gmail.com

Technical POC: Travis L. Turner, 757-864-3598, t.l.turner@nasa.gov

Description of Electronic Files Supporting Superelastic SMA Component Procurement

Geometry files for the superelastic SMA slat cover filler (SCF) and slat gap filler (SGF) parts are contained in the zip-file AT-HL-CRM_EXPORT_SURFACES_7-29-19.zip.

• SGF folder – contains subfolders of geometry files for the slat gap filler components o SFD subfolder – contains subfolders of geometry files for the stress free deployed SGF components IB subfolder – contains geometry files for the 1 SFD SGF components for the inboard slat

• sgf-sfd-1-fsp.stp – freestream-parallel inboard edge

• sgf-sfd-1-hln.stp – hinge line-normal inboard edge

• sgf-sfd-2.stp

• sgf-sfd-3.stp

• sgf-sfd-4.stp

TR subfolder – contains geometry files for the 4 SFD SGF components for the transition slat

• sgf-sfd-5.stp

OB subfolder – contains geometry files for the 8 SFD SGF components for the outboard slat

• sgf-sfd-6-fsp.stp – freestream-parallel inboard edge

• sgf-sfd-6-hln.stp – hinge line-normal inboard edge

• sgf-sfd-7.stp

• sgf-sfd-8.stp

• sgf-sfd-9.stp

• sgf-sfd-10.stp

• sgf-sfd-11.stp

• sgf-sfd-12.stp

• sgf-sfd-13.stp o SFR subfolder – contains subfolders of geometry files for the stress free retracted SGF components IB subfolder – contains geometry files for the 1 SFR SGF components for the inboard slat

• sgf-sfr-1-fsp.stp – freestream-parallel inboard edge

• sgf-sfr-1-hln.stp – hinge line-normal inboard edge

• sgf-sfr-2.stp

• sgf-sfr-3.stp

• sgf-sfr-4.stp

TR subfolder – contains geometry files for the 4 SFR SGF components for the transition slat

• sgf-sfr-5.stp

OB subfolder – contains geometry files for the 5 SFR SGF components for the outboard slat.

The most-outboard 3 components of the SFD SGF case will be reused here.

• sgf-sfr-6-fsp.stp – freestream-parallel inboard edge

• sgf-sfr-6-hln.stp – hinge line-normal inboard edge

• sgf-sfr-7.stp

• sgf-sfr-8.stp

• sgf-sfr-9.stp

• sgf-sfr-10.stp

• SCF folder – contains subfolders of geometry files for the slat cove filler components o Main subfolder – contains geometry files for the 13 main SCF components scf-main-1.stp scf-main-2.stp scf-main-3.stp scf-main-4.stp scf-main-5.stp scf-main-6.stp scf-main-7.stp scf-main-8.stp scf-main-9.stp scf-main-10.stp scf-main-11.stp scf-main-12.stp scf-main-13.stp o Reverse Auxiliary subfolder – contains geometry files for the 13 reverse auxiliary SCF components scf-rev-aux-1.stp scf-rev-aux-2.stp scf-rev-aux-3.stp scf-rev-aux-4.stp scf-rev-aux-5.stp scf-rev-aux-6.stp scf-rev-aux-7.stp scf-rev-aux-8.stp scf-rev-aux-9.stp scf-rev-aux-10.stp scf-rev-aux-11.stp scf-rev-aux-12.stp scf-rev-aux-13.stp

Please see NASA hl-crm_scf_sgf_sma_parts_list.xlsx for additional information on the interrelation of these components, their respective thickness dimensions and number of parts to be fabricated.

Other general specifications for the parts are as follows.

The provided parts shall be made of a superelastic shape memory alloy (SMA) with chemistry and heat treatment to result in an Austenite finish temperature Af of approximately 0°C or as mutually agreed between NASA LaRC and supplier as a good compromise of feasible material and component production and compatibility with test requirements. The material shall be capable of at least 10% recoverable strain with a tensile strength exceeding 160 ksi and a yield strength exceeding 48 ksi. The spanwise and chordwise dimensions of the parts prior to shape set, i.e., in the flat product form, shall have dimensions within ±0.005 inches of the provided geometry specifications and thickness dimensions within ±0.0005 inches or 10% (whichever is smaller) of the provided geometry specifications. Fastener hole locations shall be within ±0.005 inches of the provided geometry specifications. The provided parts shall also be shape-set to within ±0.005 inches of the provided geometry specifications. Any interior corner, e.g., due to trimming, shall have a radius to prevent it from being sharp and becoming a failure location.

SGF and SCF Reference Surfaces, Thickening Directions, and

Marking Notes

SGF, SFD

Top is reference

Thickness direction

Permanently mark, w/o damage, bottom surface for identification & assembly orientation

SGF, SFR

Bottom is reference

Thickness direction

SCF, Main Component

Bottom is reference

Thickness direction

Permanently mark, w/o damage, top surface for identification & assembly orientation

Avoid this section of part when marking

SCF, Reverse Auxiliary Component

Thickness direction

Bottom is reference

Permanently label top surface for identification & assembly orientation

Avoid this section of part when marking

IB Slat Transition Slat Spanwise Section 1 2 3 4 5 6 7 8 9 10 11 12 13 Main Thickness, in 0.0100 0.0090 0.0090 0.0090 0.0090 0.0090 0.0085 0.0080 0.0070 0.0070 0.0070 0.0065 0.0055

N/A N/A Aux Thickness, in 0.0100 0.0090 0.0090 0.0090 0.0090 0.0090 0.0085 0.0080 0.0070 0.0070 0.0070 0.0065 0.0055

Edge Trim Cases1 HLN HLN HLN HLN HLN HLN HLN HLN HLN HLN HLN HLN HLN Part Files (*.stp) scf-main-1 scf-main-2 scf-main-3 scf-main-4 scf-main-5 scf-main-6 scf-main-7 scf-main-8 scf-main-9 scf-main-10 scf-main-11 scf-main-12 scf-main-13 scf-rev-aux-1 scf-rev-aux-2 scf-rev-aux-3 scf-rev-aux-4 scf-rev-aux-5 scf-rev-aux-6 scf-rev-aux-7 scf-rev-aux-8 scf-rev-aux-9 scf-rev-aux-10 scf-rev-aux-11 scf-rev-aux-12 scf-rev-aux-13 # parts 3+3=6 3+3=6 3+3=6 3+3=6 3+3=6 3+3=6 3+3=6 3+3=6 3+3=6 3+3=6 3+3=6 3+3=6 3+3=6 78

# of Unique Tooling

Geometries 0

# of Unique Tooling

Geometries 0 # of Unique Tooling

Geometries 26

1All SCF parts have hingeline normal (HLN) side edges because the interchangeable IB ends of the slat have a solid section with a common HLN face that adjoins SCF section 1.

Notes:

Only tested on the OB slat and with the nacelle and pylon in place on the model.

Only one SCF design with 13 spanwise segments on the OB slat, with spanwise segmentation dicatated by slat brackets.

Each SCF spanwise section consists of two components, main and auxiliary, of matched spanwise length and thickness.

The requirement for 26 unique tools assumes each part will be shape set independently, i.e., due to furnace limitations, etc., but that tool count could be reduced by combining parts on a longer tool.

OB Slat Slat Cove Filler (SCF) Treatment

Main & Rev Aux Total

Transition Slat Section 2 3 4 1 2 3 4 5 6 7 8 Edge Trim Case1 HLN FSP HLN HLN HLN HLN HLN FSP HLN HLN HLN HLN HLN HLN HLN Thickness, in 0.0060 0.0060 0.0060 0.0050 0.0050 0.0050 0.0045 0.0045 0.0045 0.004 0.004 0.0035 0.003 0.003 0.003 Part Files (*.stp) sgf-sfd-1-hln sgf-sfd-1-fsp sgf-sfd-2 sgf-sfd-3 sgf-sfd-4 IB subtot sgf-sfd-5 Trans subtot sgf-sfd-6-hln sgf-sfd-6-fsp sgf-sfd-7 sgf-sfd-8 sgf-sfd-9 sgf-sfd-10 sgf-sfd-11 sgf-sfd-12 sgf-sfd-13 OB subtot SFD Total # Parts 6 6 6 6 6 30 3 3 3 3 3 3 3 3 3 3 3 27 60

# of Unique Tooling

Geometries 4

# of Unique Tooling

Geometries 1

# of Unique Tooling

Geometries 8

Total Unique Tooling

Geometries 13

1Edge trim cases include hingeline normal (HLN) and freestream parallel (FSP) and only the inboard end of each slat, i.e., section 1, is treated with both.

Notes:

Tested on the IB slat and OB slat when the model is configured with the nacelle and pylon.

Tested on the IB, Transition and OB slat when the model is configured without the nacelle and pylon.

SFD SGF components are stress free when bridging the gap between the main wing and the slat trailing edge.

The requirement for 13 unique tools assumes each part will be shape set independently, i.e., due to furnace limitations, etc., but that tool count could be reduced by combining parts on a longer tool.

Half of the SFD SGF components fabricated for the IB slat will be retained in the SGF assembly and the other half will go to the SCF assembly to treat that IB slat.

IB Slat OB Slat 1 1

Stress Free Deployed (SFD) Slat Gap Filler (SGF) Treatment

Transition Slat Section 2 3 4 1 2 3 4 5 6 7 8 Edge Trim Case1 HLN FSP HLN HLN HLN HLN HLN FSP HLN HLN HLN HLN HLN HLN HLN Thickness, in 0.0060 0.0060 0.0060 0.0050 0.0050 0.0050 0.0045 0.0045 0.0045 0.004 0.004 0.0035 Reuse SFD Reuse SFD Reuse SFD Part Files (*.stp) sgf-sfr-1-hln sgf-sfr-1-fsp sgf-sfr-2 sgf-sfr-3 sgf-sfr-4 IB subtot sgf-sfr-5 Trans subtot sgf-sfr-6-hln sgf-sfr-6-fsp sgf-sfr-7 sgf-sfr-8 sgf-sfr-9 sgf-sfr-10 sgf-sfd-11 sgf-sfd-12 sgf-sfd-13 OB subtot SFR Total # Parts 3 3 3 3 3 15 3 3 3 3 3 3 3 3 Reuse SFD Reuse SFD Reuse SFD 18 36

# of Unique Tooling

Geometries 4

# of Unique Tooling

Geometries 1

# of Unique Tooling

Geometries 5

Total Unique Tooling

Geometries 10

1Edge trim cases include hingeline normal (HLN) and freestream parallel (FSP) and only the inboard end of each slat, i.e., section 1, is treated with both.

Notes:

Tested on the IB slat and OB slat when the model is configured with the nacelle and pylon.

Tested on the IB, Transition and OB slat when the model is configured without the nacelle and pylon.

SFR SGF components are stress free when nested with the main-wing OML.

The requirement for 10 unique tools assumes each part will be shape set independently, i.e., due to furnace limitations, etc., but that tool count could be reduced by combining parts on a longer tool.

SFD SGF parts will be reused for sections 6, 7, and 8 of the OB slat in the SFR SGF configuration.

IB Slat 1 1

OB Slat Stress Free Retracted (SFR) Slat Gap Filler (SGF) Treatment

Procurement Specifications

Specifications

The provided parts shall be made of a superelastic shape memory alloy (SMA) with chemistry and heat treatment to result in an Austenite finish temperature Af of approximately 0°C or as mutually agreed between NASA LaRC and supplier as a good compromise of feasible material and component production and compatibility with test requirements. The material shall be capable of at least 10% recoverable strain with a tensile strength exceeding 160 ksi and a yield strength exceeding 48 ksi. The spanwise and chordwise dimensions of the parts prior to shape set, i.e., in the flat product form, shall have dimensions within ±0.005 inches of the provided geometry specifications and thickness dimensions within ±0.0005 inches or 10% (whichever is smaller) of the provided geometry specifications. Fastener hole locations shall be within ±0.005 inches of the provided geometry specifications. The provided parts shall also be shape-set to within ±0.005 inches of the provided geometry specifications. Any interior corner, e.g., due to trimming, shall have a radius to prevent it from being sharp and becoming a failure location.

SATPC0015275 Tab 4_3 SMA Specs