SATPC0034077 Tab 07 SOW_Redacted.pdf

L-PBF Parameter Development and Component Builds using GRX-810 and ORCAlloy

Statement of Work (SOW)

January 16, 2023

The National Aeronautics and Space Administration (NASA), specifically Marshall Space Flight Center (MSFC) has a need for laser powder bed fusion (L-PBF) development and component builds of novel additively manufactured (AM) NASA Alloys including ORCAlloy-21, ORCAlloy-14, GRX-810, and Alloy 754 and additional oxide dispersion strengthened (ODS) based alloys. With the various alloys being developed, L-PBF parameter optimization builds and validation are required according to custom parameter sets.

Task 1, Development Builds for AM ORCAlloy-21/14, GRX-810

1. The vendor shall provide an EOS M280 L-PBF machine with open control parameters, or equivalent, for builds using the ORCAlloy-21, ORCAlloy-14, GRX-810, Alloy 754, and other ODS-based custom NASA alloys.

2. The machine shall be made available for a minimum 432 hours per month. An estimated run time of 60% is estimated to maintain machine capacity.

3. The total period of development shall be 6 months of machine time shall be made available and include a kickoff meeting with technical points of contact (POC).

a. There is an option to run two (2) machines in parallel, but the total time will not exceed six (6) months. For example, two machines running at three (3) months each to meet component build schedules.

4. Vendor shall use custom developed parameters for the GRX-810 alloy developed under prior development work with NASA MSFC and Glenn Research Center (GRC). These parameters should result in a high density of 99.9% or greater and must be approved by NASA MSFC and GRC technical teams.

5. Additional parameter developments will be initiated for ORCAlloy-21, ORCAlloy-14, Alloy 754, other ODS-based custom NASA alloys.

6. Vendor shall notify NASA of any errors or issues during development builds.

7. Vendor shall notify NASA if powder is switched at any time to a different alloy during the

NASA alloy development builds.

8. Vendor shall complete powder removal after removal from the machine.

9. Powder lots shall be tracked on a best effort basis to determine multiple uses (for additional studies on recycled powder).

10. Vendor shall provide build records and any powder certifications associated for traceability of builds.

11. Development samples will include various metallography, mechanical testing, and parts including but not limited to injectors, nozzles, or other complex hardware.

12. Any excess powder shall be returned to NASA.

13. NASA shall provide ODS alloying of powder as needed. Vendor shall coordinate with

NASA POC’s to process powder.

14. NASA shall provide all sample geometry and models required for builds.

Task 2, Mechanical Testing of NASA AM Alloys

1. The vendor shall complete a minimum of fifty (50) mechanical tests on samples from the development builds in Task 1.

2. The testing shall include mechanical tensile and low/high cycle fatigue. Test conditions should be coordinated with the NASA technical POC and agreed upon conditions and requirements.

Task 3, Powder Development for Developmental Builds

1. The vendor shall provide the powder related to the development NASA alloys, specifically ORCAlloy-21, ORCAlloy-14, Alloy 754,. A minimum of 200 pounds shall be included to allow for developmental L-PBF builds as provided in Task 1.

2. The powder chemistry will be finalized by NASA and coordinated with the NASA technical POC and agreed upon requirements.

3. Vendor shall powder certifications associated for traceability of builds.

Shipping

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

Marshall Space Flight Center Huntsville, AL 35812

Deliverables

1. Any development samples and parts built under Task 1.

2. Test Reports from samples in Task 2.

3. Powder certifications from Task 3.