SATPC0037031 Tab 04 4 SOW Updated.pdf

Directed Energy Deposition of Large Scale Aft End JBK-75 Thin-wall Demonstrator Statement of Work (SOW)

The National Aeronautics and Space Administration (NASA), specifically Marshall Space Flight Center (MSFC) has a need for a manufacturing technology demonstration at large scale using thin-wall with the Laser Powder Directed Energy Deposition (DED) process. This is intended to complete partial developmental fabrication of a JBK-75 RS-25 aft end nozzle.

The SOW is as follows:

Task 1

1. The vendor shall prepare a large-scale build plate support an aft end of a thin-wall RS-25 nozzle demonstrator.

2. The vendor shall evaluate machine setup and weight factors of the build plate and nozzle impacting the build and provide options on build toolpaths.

3. Vendor shall evaluate final models and final build approach for a JBK-75 thin-wall RS-25 nozzle demonstrator, specifically the aft end.

4. The vendor shall provide inputs on design and develop detailed tool path approaches to be confirmed with NASA.

5. Vendor shall provide capability within laser system for 1 mm wall thickness at diameters stated in Task 1, requirement #3.

6. Vendor shall complete machine checkouts on large scale machine platform for capability to print the aft end of a RS-25 nozzle with a combined height of greater than 90” height and greater than 80” diameter.

a. Checkout prints in the form of large format build samples shall be completed to confirm operation of the trunnion table, laser system, and powder delivery system.

7. The material shall be JBK-75 Fe-Ni alloy per NASA requirements. The use of virgin powder, 1x used and 2x used is acceptable.

8. The print shall be performed within 55 consecutive days, or approximately 1,000 hours of machine time shall include the following:

a. Engineering Support for a dedicated 557 laser system (includes Tool Code generation, part design input, laser scan inspections, reporting, etc.)

b. Provide operator for machine setup and deposition.

c. Provide consumables, such as Argon nozzles, filters, and all utilities required for operation.

d. Provide a build volume at a minimum of 60” dia by 72” for component builds.

e. Provide an inert gas chamber as part of the build to minimize oxidation. Provide all argon and consumables.

f. Provide tool code required to complete large format samples.

g. Provide all maintenance on the machine during the period of builds.

h. Provide operators necessary to operate the machine.

i. Shall include other required direct costs such as consumables and necessary replacement components (inert gas, build-nozzle components, filters, etc).

j. All engineering support should be included as part of the continuous-build machine capacity. This includes all tool path generation, inspections, trouble shooting of build failures, reporting, etc.

k. Shall include removal of parts from the build plate as required.

9. Vendor shall complete a minimum deposition of 20% of the thin-wall large scale RS-25 nozzle, aft portion.

10. Part should be run on the same machine consecutively with acceptable breaks as needed for expected or unexpected shutdowns or pauses.

11. NASA shall provide drawings, models, and dimensions as required.

12. NASA will provide all heat treatments and characterization and inspections as necessary.

13. NASA shall provide DED-sized powder, specifically JBK-75, for the builds.

Shipping

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

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

Period of Performance (POP)

• 7 months from authority to proceed (ATP)

Deliverables

1. Report and any setup samples from Task 1 on the large scale aft end build.