Statement_Of_Work_for_AM_GRCop42_Combustion_Chambers.pdf

Additive Manufacturing of Large Platform GRCop-42 Chambers Statement of Work (SOW)

The National Aeronautics and Space Administration (NASA), specifically Marshall Space Flight Center (MSFC) has a need for additively manufactured combustion chambers using GRCop-42 with enhanced surface finish and increased scale.

Task 1, GRCop-42 Mechanical Characterization Samples in Large Platform

1. Vendor shall fabricate mechanical test samples, fatigue test specimens, and thermophysical test specimens using GRCop-42 additive manufacturing material and powder bed fusion (PBF).

2. The material shall be GRCop-42. MSFC shall supply powder (up to a total of 1,500 pounds for Tasks 1, 2, 3, and 4) to vendor to fabricate specimens.

3. Vendor shall fabricate a minimum of sixty (60) tensile, fatigue, and thermophysical samples for evaluation by NASA within the large platform (same machine) that the large parts will be fabricated.

4. Sample should map the entire build platform to the maximum extent (ie. Samples at 15.6” diameter as well as center)

5. Density of PBF GRCop-42 material samples shall be a minimum of 99.2% prior to any post-processing heat treatments or Hot Isostatic Pressing (HIP).

6. Surface finish should be best effort and minimized as much as possible. A desired surface finish is

<400 microinches (u-in) or better.

7. Vendor shall provide a unique identifier on each mechanical test sample to determine location on the build plate that are associated with specific build parameters.

8. Vendor shall fabricate one (1) simulator hoop 15.5” max outside diameter with integral channels.

Each hoop shall be a minimum of 1” in height.

9. The simulator hoops, witness slices and mechanical test specimens shall be removed from the build plate.

10. The simulator hoops, witness slices, and mechanical test samples shall be co-fabricated (same build).

11. Samples shall be delivered to Marshall Space Flight Center by 8 weeks After Authority to Proceed

(ATP).

Task 2, MER03142-003 (35k Full Chamber Development)

1. Vendor shall fabricate one (1) chamber per MER03142-003.stp using GRCop-42 powder bed fusion

(PBF) additive manufacturing.

2. The material shall be GRCop-42. MSFC shall supply powder (up to a total of 1,500 pounds for Tasks 1, 2, 3, and 4) to vendor to fabricate chamber.

3. Surface finish in the as-built PBF condition shall be no greater than 800 microinches verified using a profilometer. This includes the surface finish on external surfaces and internal surfaces. Vendor shall provide data relative to surface finish measurements as part of the bid package, if any prior development of GRCop material family has been completed. A surface finish of 400 microinches or less is desired.

4. Density of the material in the as-built condition shall be a minimum of 99.2% prior to any post-processing heat treatments or Hot Isostatic Pressing (HIP) operations and be demonstrated prior to fabrication of any hardware. Vendor shall provide data relative to density measurements as part of the bid package and any relevant micrographs or metallography if prior GRCop material family has been developed using PBF.

5. Vendor should provide any relevant material mechanical testing information for PBF of GRCop-42 as part of bid package. Mechanical properties of GRCop-42 material shall be demonstrated and shown to meet NASA requirements.

6. Any anomalies during the build process of the final part should be reported to MSFC Technical Point of Contact.

7. Vendor shall complete build in one-piece and remove all powder from the channels prior to further operations defined in Requirement #10.

8. Part shall not be exposed to moisture until powder from channels can be confirmed.

9. MSFC can provide CT scanning if needed to address requirement #7 and #8 or a line item in the quote could be provided to include outside vendor.

10. Part shall complete Hot Isostatic Pressing (HIP) at Pressure Technology, Inc. (Concord, OH) according to NASA processing parameters. Pressure Technology, Inc. has completed all prior development of GRCop and has defined processing operations for these type of parts. Part shall remain on the build plate for HIP operations to help with handling.

11. As-built surface finish requested, no media blasting.

12. Mechanical properties of GRCop-42 material shall be demonstrated and shown to meet NASA requirements prior to fabrication of any development hardware per Task 1, requirement #1.

13. Density and mechanical properties shall be shown to meet requirements provided across the entire build layer (outer edges of laser toolpath).

14. Vendor shall include a minimum (9) tensile specimens within each build that include unique identifiers.

15. One chamber shall be delivered to Marshall Space Flight Center by 14 weeks ATP.

16. Vendor shall provide a basic build package including any build anomalies and data relative as evidenced of process validation under documentation required by AS9100, ISO9001, or similar standard.

17. Vendor shall be ITAR registered or demonstrate ability to handle ITAR data.

Task 3, MER03747-005 (35K Liner Development)

1. Vendor shall fabricate two (2) chambers per MER03747-005 using GRCop-42 powder bed fusion (PBF) additive manufacturing.

2. The material shall be GRCop-42. MSFC shall supply powder (up to a total of 1,500 pounds for Tasks 1, 2, 3, and 4) to vendor to fabricate chambers.

3. Surface finish in the as-built PBF condition shall be no greater than 800 microinches verified using a profilometer. This includes the surface finish on external surfaces and internal surfaces. Vendor shall provide data relative to surface finish measurements as part of the bid package, if any prior development of GRCop material family has been completed. A surface finish of 400 microinches or less is desired.

4. Density of the material in the as-built condition shall be a minimum of 99.2% prior to any post-processing heat treatments or Hot Isostatic Pressing (HIP) operations and be demonstrated prior to fabrication of any hardware. Vendor shall provide data relative to density measurements as part of the bid package and any relevant micrographs or metallography if prior GRCop material family has been developed using PBF.

5. Vendor should provide any relevant material mechanical testing information for PBF of GRCop-42 as part of bid package. Mechanical properties of GRCop-42 material shall be demonstrated and shown to meet NASA requirements.

6. Vendor shall complete build in one-piece and remove all powder from the channels prior to further operations defined in Requirement #8.

7. Part shall not be exposed to moisture until powder from channels can be confirmed.

8. Part shall complete Hot Isostatic Pressing (HIP) at Pressure Technology, Inc. (Concord, OH) according to NASA processing parameters. Pressure Technology, Inc. has completed all prior development of GRCop and has defined processing operations for these type of parts. Part shall remain on the build plate for HIP operations to help with handling.

9. As-built surface finish requested, no media blasting.

10. MSFC can provide CT scanning if needed to address requirement #6 and #7 or a line item in the quote could be provided to include outside vendor.

11. Any anomalies during the build process of the final part should be reported to MSFC Technical Point of Contact.

12. Mechanical properties of GRCop-42 material shall be demonstrated and shown to meet NASA requirements prior to fabrication of any development hardware per Task 1, requirement #1.

13. Density and mechanical properties shall be shown to meet requirements provided across the entire build layer (outer edges of laser toolpath).

14. Vendor shall include a minimum (9) tensile specimens within each build that include unique identifiers.

15. A minimum of one chamber shall be delivered to Marshall Space Flight Center by 19 weeks ATP and the second chamber shall follow based on approved schedule between vendor and MSFC.

16. Vendor shall provide a basic build package including any build anomalies and data relative as evidenced of process validation under documentation required by AS9100, ISO9001, or similar standard.

17. Vendor shall be ITAR registered or demonstrate ability to handle ITAR data.

Task 4, MER03715 (META4x4 One-piece Chamber)

1. Vendor shall fabricate two (2) chambers per MER03715 using GRCop-42 powder bed fusion (PBF) additive manufacturing.

2. The material shall be GRCop-42. MSFC shall supply powder (up to a total of 1,500 pounds for Tasks 1, 2, 3, and 4) to vendor to fabricate chambers.

3. Surface finish in the as-built PBF condition shall be no greater than 800 microinches verified using a profilometer. This includes the surface finish on external surfaces and internal surfaces. Vendor shall provide data relative to surface finish measurements as part of the bid package, if any prior development of GRCop material family has been completed. A surface finish of 400 microinches or less is desired.

4. Density of the material in the as-built condition shall be a minimum of 99.2% prior to any post-processing heat treatments or Hot Isostatic Pressing (HIP) operations and be demonstrated prior to fabrication of any hardware. Vendor shall provide data relative to density measurements as part of the bid package and any relevant micrographs or metallography if prior GRCop material family has been developed using PBF.

5. Vendor should provide any relevant material mechanical testing information for PBF of GRCop-42 as part of bid package. Mechanical properties of GRCop-42 material shall be demonstrated and shown to meet NASA requirements.

6. Vendor shall complete build in one-piece and remove all powder from the channels prior to further operations defined in Requirement #8.

7. Part shall not be exposed to moisture until powder from channels can be confirmed.

8. Part shall complete Hot Isostatic Pressing (HIP) at Pressure Technology, Inc. (Concord, OH) according to NASA processing parameters. Pressure Technology, Inc. has completed all prior development of GRCop and has defined processing operations for these type of parts. Part shall remain on the build plate for HIP operations to help with handling.

9. As-built surface finish requested, no media blasting.

10. MSFC can provide CT scanning if needed to address requirement #6 and #7 or a line item in the quote could be provided to include outside vendor.

11. Any anomalies during the build process of the final part should be reported to MSFC Technical Point of Contact.

12. Mechanical properties of GRCop-42 material shall be demonstrated and shown to meet NASA requirements prior to fabrication of any development hardware per Task 1, requirement #1.

13. Density and mechanical properties shall be shown to meet requirements provided across the entire build layer (outer edges of laser toolpath).

14. Vendor shall include a minimum (9) tensile specimens within each build that include unique identifiers.

15. A minimum of one chamber shall be delivered to Marshall Space Flight Center by 24 weeks ATP and the second chamber shall follow based on approved schedule between vendor and MSFC..

16. Vendor shall provide a basic build package including any build anomalies and data relative as evidenced of process validation under documentation required by AS9100, ISO9001, or similar standard.

17. Vendor shall be ITAR registered or demonstrate ability to handle ITAR data.

OPTION: Task 5, MER03715 (META4x4 One-piece Chamber)

1. Vendor shall provide pricing of this option as part of original bid to fabricate four (4) chambers per

MER03715 using GRCop-42 powder bed fusion (PBF) additive manufacturing.

2. The material shall be GRCop-42. Vendor shall be responsible for powder procurement according to

MSFC GRCop-42 Powder Requirements, but any leftover powder from prior builds can be used as long as kept purged and meeting low oxygen content. The re-used powder shall be verified to be free of gross oxidation generally observed by blue or purple discoloration. Powder Vendors can be provided upon requests.

3. Surface finish in the as-built PBF condition shall be no greater than 800 microinches verified using a profilometer. This includes the surface finish on external surfaces and internal surfaces. Vendor shall provide data relative to surface finish measurements as part of the bid package, if any prior development of GRCop material family has been completed. A surface finish of 400 microinches or less is desired.

4. Density of the material in the as-built condition shall be a minimum of 99.2% prior to any post-processing heat treatments or Hot Isostatic Pressing (HIP) operations and be demonstrated prior to fabrication of any hardware. Vendor shall provide data relative to density measurements as part of the bid package and any relevant micrographs or metallography if prior GRCop material family has been developed using PBF.

5. Vendor should provide any relevant material mechanical testing information for PBF of GRCop-42 as part of bid package. Mechanical properties of GRCop-42 material shall be demonstrated and shown to meet NASA requirements.

6. Vendor shall complete build in one-piece and remove all powder from the channels prior to further operations defined in Requirement #8.

7. Part shall not be exposed to moisture until powder from channels can be confirmed.

8. Part shall complete Hot Isostatic Pressing (HIP) at Pressure Technology, Inc. (Concord, OH) according to NASA processing parameters. Pressure Technology, Inc. has completed all prior development of GRCop and has defined processing operations for these type of parts. Part shall remain on the build plate for HIP operations to help with handling.

9. As-built surface finish requested, no media blasting.

10. MSFC can provide CT scanning if needed to address requirement #6 and #7 or a line item in the quote could be provided to include outside vendor.

11. Any anomalies during the build process of the final part should be reported to MSFC Technical Point of Contact.

12. Mechanical properties of GRCop-42 material shall be demonstrated and shown to meet NASA requirements prior to fabrication of any development hardware per Task 1, requirement #1.

13. Density and mechanical properties shall be shown to meet requirements provided across the entire build layer (outer edges of laser toolpath).

14. Vendor shall include a minimum (9) tensile specimens within each build that include unique identifiers.

15. A minimum of one chamber shall be delivered to Marshall Space Flight Center by 36 weeks ATP and delivery date for the 2, 3, 4, units will be negotiated.

16. Vendor shall provide a basic build package including any build anomalies and data relative as evidenced of process validation under documentation required by AS9100, ISO9001, or similar

OPTION: Task 6, MER03747-005 (35K Liner Development)

1. Vendor shall provide pricing of this option as part of original bid to fabricate four (4) chambers per

MER03747-005 using GRCop-42 powder bed fusion (PBF) additive manufacturing.

2. The material shall be GRCop-42. Vendor shall be responsible for powder procurement according to

MSFC GRCop-42 Powder Requirements, but any leftover powder from prior builds can be used as long as kept purged and meeting low oxygen content. The re-used powder shall be verified to be free of gross oxidation generally observed by blue or purple discoloration. Powder Vendors can be provided upon requests.

3. Surface finish in the as-built PBF condition shall be no greater than 800 microinches verified using a profilometer. This includes the surface finish on external surfaces and internal surfaces. Vendor shall provide data relative to surface finish measurements as part of the bid package, if any prior development of GRCop material family has been completed. A surface finish of 400 microinches or less is desired.

4. Density of the material in the as-built condition shall be a minimum of 99.2% prior to any post-processing heat treatments or Hot Isostatic Pressing (HIP) operations and be demonstrated prior to fabrication of any hardware. Vendor shall provide data relative to density measurements as part of the bid package and any relevant micrographs or metallography if prior GRCop material family has been developed using PBF.

5. Vendor should provide any relevant material mechanical testing information for PBF of GRCop-42 as part of bid package. Mechanical properties of GRCop-42 material shall be demonstrated and shown to meet NASA requirements.

6. Vendor shall complete build in one-piece and remove all powder from the channels prior to further operations defined in Requirement #8.

7. Part shall not be exposed to moisture until powder from channels can be confirmed.

8. Part shall complete Hot Isostatic Pressing (HIP) at Pressure Technology, Inc. (Concord, OH) according to NASA processing parameters. Pressure Technology, Inc. has completed all prior development of GRCop and has defined processing operations for these type of parts. Part shall remain on the build plate for HIP operations to help with handling.

9. As-built surface finish requested, no media blasting.

10. MSFC can provide CT scanning if needed to address requirement #6 and #7 or a line item in the quote could be provided to include outside vendor.

11. Any anomalies during the build process of the final part should be reported to MSFC Technical Point of Contact.

12. Mechanical properties of GRCop-42 material shall be demonstrated and shown to meet NASA requirements prior to fabrication of any development hardware per Task 1, requirement #1.

13. Density and mechanical properties shall be shown to meet requirements provided across the entire build layer (outer edges of laser toolpath).

14. Vendor shall include a minimum (9) tensile specimens within each build that include unique identifiers.

15. A minimum of one chamber shall be delivered to Marshall Space Flight Center by 42 weeks ATP and delivery date for the 2, 3, 4, units will be negotiated.

16. Vendor shall provide a basic build package including any build anomalies and data relative as evidenced of process validation under documentation required by AS9100, ISO9001, or similar

Shipping

1. Contractor shall ship all deliverables and process development samples to:

Central Receiving, Bldg 4631 Attn: Paul Gradl Marshall Space Flight Center Huntsville, AL 35812

Base Deliverables

1. Base - Development samples from Task 1.

2. Base - One (1) chamber per MER03142-003 meeting all requirements under Task 2.

3. Base - Two (2) chambers per MER03747-005 meeting all requirements under Task 3.

4. Base - Two (2) chambers per MER03715 meeting all requirements under Task 4.

Summary of Base Deliverables and Options Task Part Contract QTY Delivery Date

1 Process Development Samples Base Min 60 ATP + 8 weeks 2 MER03142-003, 35k Full Chamber Dev Base 1 ATP + 14 weeks 3 MER03747-005, 35k Liner Dev Base 2 ATP + 19 weeks 4 MER03715 (META4x4 One-piece Chamber) Base 2 ATP + 24 weeks 5 MER03747-005, 35k Liner Dev Option 4 ATP + 36 weeks 6 MER03715 (META4x4 One-piece Chamber) Option 4 ATP + 42 weeks

Acronyms:

CT = Computer Tomography EDM = Electrodischarge Machining GRCop = Glenn Research Center Copper-Alloy (Cu-Cr-Nb) HIP = Hot Isostatic Pressing ITAR = International Traffic in Arms Regulations MSFC = Marshall Space Flight Center NLT = No Later Than PBF = Powder Bed Fusion

References

GRCop-42 Alloy Argon Gas Atomized Powder Specification

1. Contractor shall provide GRCop-42 Alloy powder to the following specifications:

a. Chemistry to included Table

b. XX lbs (minimum)

c. Powder is to be Argon Gas Atomized

(Atomization in nitrogen is not an acceptable alternative.)

d. Spherical Particles with Particle Size Distribution of -325 mesh

Powder Specification Table

Component Wt % Wt Ratio Cr 3.10 – 3.40 (3.26 – 3.40 desired) Nb 2.7 – 3.0 (2.90 – 3.00 desired) Fe Target <50 ppm; Max 250 ppm O Target <400 ppm; Max 700 ppm Al <50 ppm; maximum 150 ppm Si <50 ppm; maximum 150 ppm Cu Balance

Cr/Nb* 1.08-1.21

*Cr:Nb ratio: Aim - 2.03 Cr:Nb ratio by atomic percent / 1.14 Cr:Nb ratio by weight percent

Desired Range – 2.01 to 2.05 Cr:Nb by atomic percent /

1.12 to 1.15 Cr:Nb ratio by weight percent

Allowed Range – 1.95 to 2.15 Cr:Nb by atomic percent /

1.08 to 1.21 Cr:Nb ratio by weight percent

2. Certification of chemistry and particle-size distribution (PSD) report to ASTM standards is required.

Powder from more than one production lot may be mixed to obtain the total amount of powder required. However, prior to mixing, the chemistry of each lot must be obtained, and it must fall within the limits specified. Any powder lot not meeting the chemistry requirement shall be rejected. Mixing shall be done in an inert atmosphere or vacuum.

3. Less than 2% by volume of the powder shall be greater than 45 microns in diameter

4. Powder is to be delivered in individual 20 pound Argon back-filled (metal preferred) containers and be handled in an inert gas or vacuum environment to reduce exposure to oxygen. Plastic bags may not be used for the storage and shipping of the powder.

5. Vendor shall document any prior experience providing GRCop-42 or GRCop-84 powder that was used in the powder-bed fusion (PBF) or selective laser melting (SLM) process. Vendor with proven experience with powder that has been certified via chemistry and demonstrated during SLM process is preferred.