3D_Weave_Dev_SOW-1-23-2018.docx

NASA - Composite Technology for Exploration Bally Ribbon Mills 3D Weave Circumferential End Ring-Frame Fabrication and Consultation Statement of Work (SOW) – 23 Jan 2018

1. Background: The Composite Technology for Exploration (CTE) Project is developing and demonstrating critical composites technologies focusing on joint materials, design/analysis, manufacturing, and tests that utilize NASA and industry joint expertise and capabilities. The work is advancing lightweight structures to support future NASA exploration missions while also advancing the state of the art in the detailed analyses of composite bonded joints and the interactions of their stress-strain fields with local design features. In particular, the CTE project is demonstrating weight-saving, performance-enhancing joint technology for Space Launch System (SLS)-scale composite hardware. Circumferential joints ends rings interfacing cylindrical and conical structures are of particular interest offering significant mass reduction opportunities.

2. Objectives: This SOW details tasks and deliverables to support CTE project design and analyses efforts, and demonstrate materials and designs based the Composite Material Handbook building block approach. This work provides developments leading to an 8.4m scale 3D woven carbon fiber end ring joint design for an SLS class vehicle. The building block approach implementation includes providing a weave with a joint intersection for test evaluations, and an end ring component straight section with all design features for additional test evaluations. This SOW details the requirements for the 3D woven dry preforms for delivery, consultations enabling analyses and weave quality assessments, and implementation of weave quality assurance per task plan below.

3. Task Requirements:

3.1. Meetings and Trips

3.1.1. CONTRACTOR shall support a kickoff meeting at Contractor’s site

3.1.2. CONTRACTOR shall meet once a month by telecon, for an hour, to discuss work status during the period of performance

3.1.3. CONTRACTOR shall support one trip to Marshall Space Flight Center, Huntsville, AL to participate in 3D weave presentation to Management.

3.2. Problem Reporting

3.2.1. CONTRACTOR shall inform NASA in the event of non-conformances in manufacturing processes within two weeks of an occurrence. Report shall include problem description, delivery impact and the problem resolution plan.

3.3. 3D Weaving

3.3.1. CONTRACTOR shall make all parts with AS4 fiber, 12K tow or 6K tow, as the design dictates

3.3.2. Flat plate with Single leg at 35 degree angle (Figure 1)

3.3.2.1. GSFC shall provide estimated thickness requirement for the flat plate and the protruding leg in drawing #CTE-400, released after the contract is award. This will assume an orthogonal weave architecture.

3.3.2.2. CONTRACTOR shall recommend weave changes and define the weave at the intersection of the two parts. Figure 1: Single Leg graphic

3.3.2.2.1. Definition of weave at the intersection means providing fiber paths and translating that into analytical modeling parameters

3.3.2.2.2. Recommendation and final configuration will be approved by GSFC

3.3.2.3. CONTRACTOR shall provide inputs to the Single Leg Resin Transfer Mold (RTM) tool design team and provide final review of RTM tool design

3.3.2.4. CONTRACTOR shall fabricate 300 linear inches of the single leg configuration.

3.3.3. End Ring Component (Figure 2) Figure 2: End Ring Component Graphic

3.3.3.1. GSFC shall provide estimated thickness requirement for the end-ring component in drawing #CTE-401, released after the contract award. This will assume an orthogonal weave architecture.

Note: End Ring Component will be a straight section.

3.3.3.2. CONTRACTOR shall recommend weave changes and define the weave differences.

3.3.3.2.1. Definition of weave means providing fiber path and translating that into analytical modeling parameters

3.3.3.2.2. Recommendation and final configuration will be approved by GSFC

3.3.3.3. CONTRACTOR shall provide inputs to the End Ring RTM tool design team and provide final review of RTM tool design

3.3.3.4. CONTRACTOR shall fabricate 450 linear inches of this configuration.

3.4. Quality Control Assessment

3.4.1. CONTRACTOR shall report 3D weave variables that affect weave manufacturing as well as current fiber weaving quality control measurements taken.

3.4.2. CONTRACTOR shall recommend tests that could correlate weave variables to structural performance.

3.4.3. CONTRACTOR shall propose additional quality control measurements that can result in better weave manufacturing verifications and/or more directly relate to structural performance.

3.5. Define the manufacturing machine design changes and costs associated with taking the End-Ring component design as a straight section per paragraph 3.3.3 leading to a 8.4 meter diameter end ring design configuration.

4. Deliverables and Delivery Dates –

4.1. Delivery and invoicing. Each deliverable is to be a separate payable invoice.

4.2. Support a kickoff meeting at CONTRACTOR – 1 month after receiving order (ARO)

4.3. Trip to Marshall Space Flight Center, Huntsville, AL - TBD Date in 2018

4.4. 3D Weaving, Infusion and Cure

4.4.1. Flat plate with Single leg at 35 degree angle deliverables

4.4.1.1. CONTRACTOR shall recommend weave changes per paragraph 3.3.2.2

– 1 week after GSFC defines thicknesses per paragraph 3.3.2.1

4.4.1.2. CONTRACTOR shall fabricate 300 linear inches of this configuration.

– 2 months after approval from GSFC per 3.3.2.2.2

4.4.2. End Ring Component deliverables

4.4.2.1. CONTRACTOR shall recommend weave changes and define the weave differences per paragraph 3.3.3.2

– 1 week after GSFC defines thicknesses per paragraph 3.3.3.1

4.4.2.2. CONTRACTOR shall fabricate 450 linear inches of this configuration

- 3 months after approval from GSFC per 3.3.3.2.2

4.5. Quality Control Assessment Deliverables

4.5.1. CONTRACTOR shall provide 3D quality control assessment report per paragraphs 3.4.1, 3.4.2 and 3.4.3

– 4 months ARO

4.6. Define the design changes and costs associated with taking the End-Ring component design as a straight section leading to an 8.4m diameter design configuration per paragraph 3.5.

1 month after End Ring Component delivery

4.7. Delivery to

Ken Segal NASA/ Goddard Space Flight Center Code 543 Building 5, Room C200B Greenbelt, MD, 20771

PH 301-286-2895

5. Period of Performance: Award of Contract – Dec 1, 2018 image1.png image2.png