80NSSC20728165Q - SOW.pdf

DOC NUMBER SITB-2020-009

INITIAL RELEASE

RELEASE DATE: MARCH 25, 2020

Fiber Optic Sensing System (FOSS)

Shock Testing Statement of Work

National Aeronautics and Space Administration

Revision: Final Document No: SITB-2020-009 Release Date: 03/25/2020 Page: 2 of 20 Title: FOSS Shock Testing Statement of Work

Release Date: 03/25/2020 Page: 3 of 20

REVISION HISTORY PAGE

Revision No. Description Release Date

Draft Draft 2/10/2020

Baseline Initial Release 03/25/2020

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Table of Contents

1.0 Testing Phases

2.0 Requirements

2.1 Phase 1 Requirements

2.2 Phase 2 Requirements

2.3 Phase 3 Requirements

3.0 Government furnished Equipment

3.1.1 Interface Plate to the Contractor’s Test Hardware/Machine

3.1.2 Summary of Weights of Government Furnished Test Articles

4.0 Contractor Provided Hardware

4.1 Interface Hardware Design

4.2 Interface Hardware Fabrication

4.3 Mass Model

4.4 Attachment Fasteners

5.0 Shock Testing

5.1 Shock Testing General

5.2 Shock Test Spectra

5.2.1 Qualification Level Spectra

5.2.2 Protoqualification Level Spectra

5.3 Shock Test Tolerances

5.4 Instrumentation and Data Requirements

5.5 Functional Testing

5.6 Test Procedures

5.7 Test Readiness Review

5.8 Hardware Handling

5.9 Cleanliness and Contamination Control

5.10 Government Staff on-site during testing

5.11 Government Quality Assurance

5.12 Government Engineering Staff

6.0 Government Furnished Information

7.0 Deliverables

8.0 Schedule

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Appendix A: Acronyms

List of Figures Figure 2-1. FOSS Assembly mounted on Test Plate Figure 3-1. FOSS Interface plate to Contractor’s test machine Figure 5-1. Shock Test Profile for the Qualification Level Assembly

List of Tables

Table 3-1. GFE test article and interface hardware list PER SET Table 3-2. Test Assembly Approximate Weight Breakdown Table 5-1. Shock Input Spectra for the Qualification Level Assembly Table 6-1. Government Furnished Information Table 7-1. Contractor Deliverable Documents and Data For Phase 2 Table A-0-1: Acronyms

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1.0 TESTING PHASES

The LOFTID project is intending on shock qualifying up to four Fiber Optic Sensing System (FOSS) assemblies.

This statement of work covers three phases:

The government would like to treat each phase as a different statement of work. Successful completion of phase 1 will be required for phase 2. Phase 3 testing is only required if phase 2 testing produces undesired results.

For Phase 1: The government is asking for a demonstration prior to final award that the test facility can meet the required qualification shock spectrum with a similar payload and footprint of the FOSS box, in each orthogonal direction. The deliverables for phase 1 is documentation that the spectrum can be achieved, i.e., photographs of setup, shock response spectrum response data.

For Phase 2: Upon successful completion of phase 1, the government will exercise the option to have the contractor complete phase 2. If the contractor is unable to demonstrate the requirements of phase 1, the government will not exercise the option for the contractor to complete phase 2. Phase 2 consists of testing the FOSS qualification unit.

For Phase 3: If the qualification unit has acceptable results, the three flight units will not be subjected to shock testing at acceptance levels and there will be no phase 3 of testing.

However, if the qualification unit fails to meet success criteria during phase 2 testing, the other three units will undergo protoqualification testing, in Phase 3 OR there will be a retest of a modified design for the qualification unit. Depending on the failure mechanism of the qualification unit, there may be a time delay between Phase 2 and Phase 3 testing.

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2.0 REQUIREMENTS

2.1 Phase 1 Requirements

The contractor shall:

1) Use a mass and footprint similar to those outlined in Sections 3.1.1 and 3.1.2 of this document to show that the contractor can achieve the nominal shock spectrum defined in Section 5.2.1 of this document.

2) Preform the specified demonstration testing using a tunable beam style shock machine.

3) Perform the demonstration testing in all three orthogonal directions.

4) The deliverables for this phase are:

a. A summary document with the test set up and SRS results from that set up.

b. An estimate of how long phase 2 shock testing will take.

2.2 Phase 2 Requirements

The qualification FOSS unit will be tested in all three principle directions, three times, for a total of nine shocks. The test articles and the necessary test support equipment will be provided by the government along with the essential government staff to operate the GFE. The qualification unit is shown in

The contractor shall:

1) Provide the needed test interface hardware between the GF test articles and the contractor’s test facility

2) Perform the specified shock testing on a tunable beam style shock machine

3) Provide the test data and reports.

FIGURE 2-1. FOSS ASSEMBLY MOUNTED ON TEST PLATE

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2.3 Phase 3 Requirements

If the government elects to have phase 3 be a retest of the qualification unit, the requirements for phase 3 are identical to phase 2.

If the government elects to have phase 3 be a protoqualification three FOSS assemblies will be tested. If this option is exercised, each protoqualification unit will be tested in all three principle directions, two times, for a total of six shock per assembly, for 18 total shocks entirely. The test articles and the necessary test support equipment will be provided by the government along with the essential government staff to operate the GFE.

In either scenario the contractor shall:

1) Provide the needed test interface hardware between the GF test articles and the contractor’s test facility

2) Perform the specified shock testing on a tunable beam style shock machine

3) Provide the test data and reports.

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3.0 GOVERNMENT FURNISHED EQUIPMENT

There are four identical sets of government sets furnished test articles one set for phase 2 and up-to three sets for phase 3, if needed. There is a single set of government furnished test interface hardware that will be used with each test article. The GFE and interface hardware list per set is found in Table 3-1.

TABLE 3-1. GFE TEST ARTICLE AND INTERFACE HARDWARE LIST PER SET

Description Material Quantity FOSS Assembly Various 1 Mounting fasteners (NAS1351-N5-14) Steel 27 Washers (NAS1587-5C) Steel 27 5/16-24 Key Locking Keensert (PN 90245A073) Carbon Steel 27 Test interface plate AL 6061-T6 1 Test interface fasteners

(PN 91251A372)

Grade 8 38

Broadband Reflectors Various 4

The Government will provide the necessary test interface to enable the government furnished test articles to be integrated to the Contractor test facility. The current drawings for this hardware are sufficiently complete to provide the relevant interface requirements to the Contractor. The final approved drawings will be provided to the Contractor as noted in Section 6.0.

3.1.1 Interface Plate to the Contractor’s Test Hardware/Machine

Shown in Figure 3-1 is the government furnished interface plate that will attached the test assemblies to the contractor’s provided interface and mounting hardware. This plate is nominally 22.5” x 30.5” x 1” aluminum (6061-T6) plate. There are 38 fastener holes around the interface plate that will be used for mounting the GFE interface plate to the contractor’s test machine and 27 mounting fastener locations for mounting the FOSS assembly to the interface plate. The 8 fastener holes on the interface plate that are underneath the FOSS assembly will not be used for shock testing. There are four broadband receivers that will also be mounted to the interference plate during shock testing.

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FIGURE 3-1. FOSS INTERFACE PLATE TO CONTRACTOR’S TEST MACHINE

3.1.2 Summary of Weights of Government Furnished Test Articles

The approximate weights of the components for each FOSS assembly to be placed on the shock test machine are provided in Table 3-2.

It is requested that the contractor provide the weights of any additional fixtures needed to achieve each shock direction in the finalized shock test report.

TABLE 3-2. TEST ASSEMBLY APPROXIMATE WEIGHT BREAKDOWN

Component Test Article (pounds)

Interface Plate (pounds)

Interface Hardware (pounds)

Total Weight (pounds)

FOSS Assembly 34.2 67.3 10 127.3

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4.0 CONTRACTOR PROVIDED HARDWARE

4.1 Interface Hardware Design

The Contractor shall develop the detailed design of the necessary hardware to interface between the GFE shown in Table 3-2 and the Contractor’s shock testing facility.

The contractor shall submit the drawing showing the bolt pattern to be used for mounting the GFE to the Contractor Interface hardware at least 15 calendar days prior to the start of the machining of the Contractor Interface Hardware (Item 1 in Table 7-1). The Government will provide comments to the Contractor within 5 calendar days of receipt of the drawing(s).

4.2 Interface Hardware Fabrication

The Contractor shall fabricate the hardware needed to interface between the GFE and the Contractor’s shock testing facility.

4.3 Mass Model

The contractor shall develop a mass model to be used during the tuning phases of the shock testing (Item 2 in Table 7-1). The mass model should have an identical bolting pattern and use the same size and type of fasteners, keylocks, washers, and bolts, as the test assembly. The government will provide the FOSS mass and CG information 30 days prior to the start of shock testing.

4.4 Attachment Fasteners

All fastener hardware needed to attach the Government Furnished Hardware to the Contractor’s shock testing facility shall be provided by the Contractor.

The Contractor shall provide the recommended torque values for attaching the Government Furnished Interface Plate to the Contractor’s shock test facility to the Government at least 20 calendar days prior to the start of the shock testing (Item 3 in Table 7-1). The Government will provide concurrence with the bolt torque values prior to the installation of the Government Furnished Interface Plate.

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5.0 SHOCK TESTING

The contractor shall provide all elements necessary to perform the shock testing, capture the specified data, and provide the requested test reports (Items 7 through 11 in Table 7-1).

The following requirements are applicable to all four shock test articles.

5.1 Shock Testing General

The contractor shall perform the shock testing using a tunable beam approach.

Each test article shall be shock tested separately.

Each test article shall be subjected to a shock test in each of the three axes.

Each shock test shall be performed for a single axis; multi-axis shock test shall not be performed for this testing. The order of the axes tested is at the discretion of the Contractor and/or Government representative if a primary axis is of concern.

The qualification test article shall be subjected to three shocks per axis, one axis at a time.

The Contractor shall perform the shock test tuning phase using a contractor furnished mass model of the

FOSS.

A minimum of three satisfactory tuning shocks will be required per axis, per test article.

If Phase 3 is required, and the government elects to do a protoqualification on the remaining three FOSS units, each shall be subjected to two shocks per axis, one axis at a time.

5.2 Shock Test Spectra

The contractor shall ensure the synthesized shock waveform has a time history that is oscillatory in nature.

The contractor shall ensure the shock pulse decays to less than 10% of its peak value within 20 milliseconds after the impulse is applied.

The contractor shall ensure that at least 50% of the maximum spectrum values exceed the nominal spectrum.

The shock test will conform to the requirements in SMC Standard SMC-S-016, Test Requirements for Launch, Upper-Stage and Space Vehicles.

5.2.1 Qualification Level Spectra

The shock response spectrum for the qualification level assembly is detailed in Table 5-1 and plotted in Figure 5-1. Figure 5-1 contains a suggested nominal tuned beam SRS (100 Hz and 170 g, 1,400 Hz and 3,777 g). It is requested that the contractor try and stay within the bounds of the FOSS SRS as much as possible. If the contractor and government find a more suitable SRS during the tuning phase of testing, that is allowed.

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TABLE 5-1. SHOCK INPUT SPECTRA FOR THE QUALIFICATION LEVEL ASSEMBLY

Frequency (Hz) Nominal Level Lower Bound Level Upper Bound Level 100 170 g 85 g 339 g 175 299 g 150 g 597 g

300-700 848 g 425 g 1,692 g 1,400-3,000 2,195 g 1,100 g 4,380 g

7,000-10,000 5,986 g 3,000 g 16,871 g

FIGURE 5-1. SHOCK TEST PROFILE FOR THE QUALIFICATION LEVEL ASSEMBLY

5.2.2 Protoqualification Level Spectra

If protoqualification is required for Phase 3 testing, the government will supply a spectrum and tolerance values at that time. The levels will be less than those shown in section 5.2.1.

1,000

10,000

100,000

100 1,000 10,000

SR

S

(g

Frequency (Hz)

Qualification Test SRS for FOSS Assembly

FOSS Nominal SRS Lower Limit (-6 db)

Upper Limit (+6 dB/+9 dB) Nominal Tuned Beam

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5.3 Shock Test Tolerances

The contractor shall ensure the measured maximum shock response spectrum has a minimum resolution of 1/12 octave frequency band and be calculated using a constant quality factor Q of 10 per NASA-STD- 7003A.

The shock test spectra at the control location shall be within +/- 6 dB of the values in Table 5-1 over the frequency range of 100 to 3,000 Hz and within +9/-6 dB of the values Table 5-1 over the frequency range of 3,000 to 10,000 Hz, per SMC-S-016. If there is a discrepancy between Table 5-1 the associated figure (Figure 5-1), then the data from the Tables shall be used.

The contractor shall ensure that at least 50% of the maximum spectrum values exceed the nominal values noted in Table 5-1.

5.4 Instrumentation and Data Requirements

The contractor shall mount control and monitor accelerometers on the test fixture near the test article attachment point on the surface of the composite representative structure at mutually agreeable locations. The contractor shall use a threaded inserted based approach for attaching the control and monitoring accelerometers. The contractor shall submit the recommended mounting locations for the control and monitoring accelerometers to the government at least 20 calendar days prior to the start of the installation of the government furnished test articles (Item 5 in Table 7-1).

The control shock spectrum at the control accelerometer shall be matched to the required spectrum.

Time history data from control and monitoring accelerometers shall be recorded and preserved.

The contractor shall use their existing data acquisition system to collect and record all of the necessary data for the shock testing reports.

All measurement and test equipment shall be calibrated and calibration records shall be available for NASA review and included in the final test report. Calibration and accelerometer mounting shall be in accordance with ISO or equivalent standards for shock measurements.

Shock response spectra and pulse data shall be provided in units of G’s. Graphical representation of the shock data and test requirement levels with respect to frequency shall be provided for each test article in each of the three orthogonal directions tested (Items 8 and 11 in Table 7-1).

The test articles shall photographed by the contractor from multiple angles before and after each shock test run and prior to installing and uninstalling the test articles from the test fixture (Item 9 in Table 7-1).

High speed video of test articles shall be taken during each shock test run (excluding the tuning shocks with the mass models) (Item 10 in Table 7-1).

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5.5 Functional Testing

GFE will be connected to the each FOSS assembly during the shock testing so that live monitoring of the test article sensors can occur during testing. The government will be responsible for operating the GFE.

The government will also conduct pre and posttest functional tests between each shock and each axis of shock testing. Government personnel will perform this step by connecting GFE to the FOSS assembly.

5.6 Test Procedures

The contractor shall develop and provide a test procedure to the government 20 calendar days before the start of the installation of the test article (Item 4 in Table 7-1). The government will provide comments and concurrence to the procedure within 10 calendar days of receipt of the procedure.

5.7 Test Readiness Review

The contractor’s test facility personnel shall participate in a Test Readiness Review (TRR) via telecon within 5 calendar days prior to the scheduled test start. Prior to this review, the test procedure shall be finalized and the ability of the facility to meet the required test conditions shall be demonstrated. Telecon arrangements will be made by government personnel in coordination with the shock test facility personnel.

5.8 Hardware Handling

Government personnel will be responsible for all handling, assembly, packing, and shipping of test articles and GSE.

The contractor (supported by government personnel) will be responsible for integration of the test articles and interface hardware to the facility interface.

5.9 Cleanliness and Contamination Control

The four FOSS assemblies shall be considered Electro Static Discharge (ESD) sensitive.

The contractor shall use their existing ESD Control Program approach for ensuring ESD protection for the Government Furnished test articles. If such a control program does not exist for the contractor the government and the contractor will develop a procedure to use during shock testing that is compliant with the technical requirements in Section 8 of ANSI/ESD S20.20-2014.

The FOSS Assemblies will be covered or placed in ESD approved clean bagging material when not being used or operated.

5.10 Government Staff on-site during testing

The government will have staff at the Contractor’s facility during the shock testing to support the testing, perform the functional testing of the test articles, and provide QA support. The government will have up to five (5) staff at the Contractor’s facility during the shock testing.

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5.11 Government Quality Assurance

Government Quality Assurance (QA) staff will support the testing. The Government QA staff will review and sign-off on the government procedures associated with the assembly of the government test articles (see Section 3.0) and the government performed functional testing.

The Government QA staff will support the shock testing of the qualification hardware (support during the shock level tuning with the mass simulators is not necessary). The Government QA staff will verify Contractor compliance with test procedures by participating in test operations to monitor and/or witness each step, as required.

5.12 Government Engineering Staff

The Government will provide up to four (4) staff total of engineers and technicians to:

a) Perform the necessary post shipping hardware inspection and functional testing

b) Perform the assembly of the government test articles and the government interface hardware

c) Support the Contractor as necessary during the integration of the government test articles and the government interface hardware to the Contractor facility and hardware

d) Perform the functional tests as part of the overall shock testing

e) Pack and ship the government furnished test articles and interface hardware for return to Langley Research Center

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6.0 GOVERNMENT FURNISHED INFORMATION

The government will provide the following information to the Contractor as noted below in Table 6-1.

TABLE 6-1. GOVERNMENT FURNISHED INFORMATION

No. Description Delivery Date to the Contractor 1 Government developed final FOSS Shock Test Plan No Later than 30 calendar days after contract award 2 Final approved drawings of the Government Furnished

Interface/Load Introduction Hardware (see Section 3.1.1) No Later than 30 calendar days after contract award 3 Final mass information of the Government Furnished

Hardware (see Section 3.1.2) No Later than 45 calendar days after contract award

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7.0 DELIVERABLES

The contractor shall provide the reports and data as indicated in Table 7-1.

TABLE 7-1. CONTRACTOR DELIVERABLE DOCUMENTS AND DATA FOR PHASE 2

No. Description Required Completion Date 1 Drawing of the interface plate between the GFE and the contractor shock test facility.

Government will provide comments to the Contractor within 5 Calendar days of receipt of the drawings

15 calendar days prior to start of machining

Drawing of the mass model.

Government will provide comments to the Contractor within 5 Calendar days of receipt of the drawings

15 calendar days prior to start of machining

2 Bolt torque values for the bolts used to attach the Government Furnished Interface Plate to the Contractor’s shock test facility Government will provide concurrence to the bolt torque values within 5 Calendar days of receipt of the recommended values.

20 calendar days prior to the installation of the

Government Furnished Interface Plate.

3 Contractor Shock Test Procedure Government will provide comments to the Contractor within 10 Calendar days of receipt of the drawings

20 calendar days prior to the start of the installation of the test hardware 4 Contractor Recommended mounting location for the control and monitoring accelerometers.

Government will provide comments to the Contractor within 10 Calendar days of receipt of the recommended mounting locations.

20 calendar days prior to the start of the installation of the test hardware

5 As Run Test Procedure in PDF Format 5 calendar days after completion of shock testing

6 Raw data including shock response spectrum (SRS) and time histories in text format

5 calendar days after completion of shock testing

7 Plots of All Data collected 10 calendar days after completion of shock testing

8 Photos of Test Articles and Test Configuration Before and After each Shock Test Run (Note this does not include the tuning shocks with the mass simulator)

5 calendar days after completion of shock testing

9 High speed video of test articles during each shock test run (Note this does not include the tuning shocks with the mass simulator)

5 calendar days after completion of shock testing

10 Test Summary Report to include description of test setup with photos, instrumentation list, equipment list, plots of all SRS data and time histories from all recorded data channels, and photos of test articles before and after each shock test run

30 calendar days after completion of shock testing

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8.0 SCHEDULE

The government and the Contractor shall establish a mutually agreeable test period within 30 calendar days of award of the contract.

The government estimates that all shock testing and report submission should be complete within 20 business days of the start of shock testing.

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APPENDIX A: ACRONYMS

Table A-0-1: Acronyms

Acronym Definition CG Center of Gravity dB Decibel ESD Electro-static Discharge GF Government Furnished GFE Government Furnished Equipment Hz Hertz IPA Isopropyl Alcohol ISO International Standards Organization KSC Kennedy Space Center LaRC Langley Research Center NASA National Aeronautics and Space Administration QA Quality Assurance SITB Systems Integration and Test Branch SRS Shock Response Spectrum TRR Test Readiness Review