DRAFT -Tailpiece Performance Work Statement.pdf

PERFORMANCE WORK STATEMENT (PWS)

COLD SPRAY REPAIR OF THROTTLING VALVE TAILPIECE

1. GENERAL: This is a non-personnel services contract to provide a cold spray procedure for the cold spray repair of MCW throttling valve tailpiece. The Government shall not exercise any supervision or control over the contract service providers performing the services herein. Such contract service providers shall be accountable solely to the Contractor who, in turn is responsible to the Government.

1.1. Description of Services/Introduction: The contractor shall provide all personnel, equipment, supplies, facilities, transportation, tools, materials, supervision, and other items and non-personal services necessary to perform the development of a cold spray procedure for the cold spray repair of the MCW throttling valve tailpiece as defined in this Performance Work Statement except for those items specified as government furnished property and services. The contractor shall perform to the standards in this contract.

1.2. Background: The Puget Sound Naval Shipyard and Intermediate Maintenance Facility (PSNS &

IMF) requires the development of a qualified spray procedure (QSP) and the cold spray repair of 4

(ea.) throttling valve tailpieces, pc-7 of reference (a).

1.2.1. Details of cold spray test coupons required for QSP development are shown in reference (b).

1.2.2. MCW throttling valve tailpiece is approximately 16-1/2” in diameter, 2-3/4” tall, made from

Copper-Nickel 70-30. Repair area is approximately .06” deep on a 10-3/4” to 12-1/2” conical inside diameter. See reference (c) for spray location and details.

1.3. Objectives:

1.3.1. Develop a qualified spray procedure for the cold spray repair of a throttling valve tailpiece.

1.3.2. Cold spray repair 4 (ea.) throttling valve tailpieces.

1.4. Scope: Services include manufacture, cold spray, and testing of test specimens. Services also include the cold spray and testing of cold spray mock ups and 4 (ea.) throttling valve tailpieces. The contractor shall accomplish the following.

1.4.1. Qualified Spray Procedure Development

1.4.1.1. References

(a) NAVSEA drawing 4674165 rev B Excerpt

(b) Qualified Spray Procedure Test Coupon Details

(c) Tailpiece, PC-7, Cold Spray Mockup, Code 260M sketch [PC-7 tailpiece mockup.dft]

(d) QSP-4674165-7-03-S.docx

(e) CSAR-LAC-0001.docx (MCW-5)

(f) CSAR-LAC-0003.docx (MCW-6)

(g) CSAR-LAC-0005.docx (MCW-7)

(h) CSAR-LAC-0007.docx (MCW-8)

1.4.1.2. General Requirements

1.4.1.2.1. Qualified spray procedure development and cold spray repair shall be accomplished with a VRC

Gen III or VRC Gen III Max cold spray system.

1.4.1.2.2. Cold spray test samples shall be prepared and cold sprayed with the same critical parameters

(denoted on reference (d)) as the final parts will be sprayed. Modification of critical parameters to achieve satisfactory results shall require re-accomplishment of any previously completed testing.

1.4.1.2.3. Cold spray test coupons shall be wrought, forged, or cast 70-30 copper-nickel.

1.4.1.2.4. Unless otherwise specified, vendor is responsible for manufacturing test coupons and accomplishing all testing.

1.4.1.2.5. Complete blocks 11 through 16 of reference (d) prior to application and testing of cold spray.

1.4.1.3. Adhesion Testing, Bond

1.4.1.3.1. Adhesion testing by the vendor is not required, but will be accomplished by the PSNS laboratory. Samples shall be supplied by the vendor for testing. Acceptance is 3,000 psi minimum bond strength. No single value shall be below the minimum acceptable bond strength.

1.4.1.3.2. Manufacture 12 (ea.) bond buttons per reference (b). Substrate and fixture bond buttons are dimensionally equivalent. Fixture bond buttons are uncoated, substrate bond buttons are cold spray coated.

1.4.1.3.3. Prep and cold spray 5 (ea.) substrate bond buttons. Cold spray coating thickness to be .020” minimum after finish machining. Finish machine coating to achieve a surface finish of 100 to

200 RHR and perpendicularity to the bond button axis within .003”.

1.4.1.3.4. Deliver bond buttons to PSNS per paragraph 1.5.1.

1.4.1.4. Mechanical Property Testing

1.4.1.4.1. Manufacture 3 (ea.) tensile test coupons per ASTM E8/E8M-15a, figure 1, sheet type. Test specimens shall be machined from a bulk cold spray tensile specimen per reference (b) and shall be a minimum of .250” thick after finish machining.

1.4.1.4.2. Tensile test is not a cohesion/adhesion test, so any substrate is acceptable provided the cold spray can be successfully built up using the required critical parameters.

1.4.1.4.3. Test cold spray samples for tensile strength, yield strength, and elongation.

1.4.1.4.4. Record test results on reference (d).

1.4.1.5. Corrosion Testing Data

1.4.1.5.1. Corrosion testing is accomplished during development of the associated valve body cold spray

QSP.

1.4.1.6. Metallographic Mock-Up Testing

1.4.1.6.1. Receive 1 (ea.) throttling valve tailpiece mock-up from PSNS. Mock-up ring is forged 70/30 copper-nickel.

1.4.1.6.2. Prep and cold spray 1 (ea.) throttling valve tailpiece mock-up. Ensure sufficient build up is applied to finish machine tailpiece sealing surface smooth and fair with adjacent material.

1.4.1.6.3. Finish machine mock-up per reference (c). Inspect mock-up during and subsequent to machining per paragraph 1.4.1.7. Ensure all overspray is removed. Document final tailpiece sealing surface as “fair with adjacent metal” in block 17 of reference (d).

1.4.1.6.4. Accomplish visual inspection per paragraph 1.4.1.8.

1.4.1.6.5. Accomplish ring testing per paragraph 1.4.1.9.

1.4.1.6.6. Section mock-up to allow examination of sealing surface (tailpiece inside diameter). Examine both ends of the cold spray coating as well as the coating in the middle of the sealing area.

1.4.1.6.7. Examine mock-up for oxides and porosity per MIL-STD-3021 paragraphs 5.2.2 and 5.2.3.

1.4.1.6.8. Acceptance criteria is 3% maximum oxides and 2% maximum porosity. If chrome-carbide is added to the nickel as a duplex powder (part of the final matrix), the chrome-carbide shall not be considered an oxide per this requirement.

1.4.1.6.9. There shall be no evidence of classification (significant changes in powder ratios through thickness of spray) for duplex (blended) powders.

1.4.1.6.10. Final metallographic examination will be accomplished by the PSNS laboratory. Record test results in block 19 (remarks) of reference (d). MEm test results in block 18 will be completed by

PSNS.

1.4.1.6.11. Deliver sectioned samples and remaining portions of the mock-up to PSNS per paragraph 1.5.2.

1.4.1.7. Adhesion Testing, Machining

1.4.1.7.1. During and subsequent to finish machining, visually inspect cold spray coating.

1.4.1.7.2. Acceptance criteria is no signs of delamination, cracking, or lack of adhesion.

1.4.1.7.3. The following conditions shall not be cause for rejection.

1.4.1.7.3.1. Breaking off excess cold spray provided the remaining cold spray is tightly adhered.

1.4.1.7.3.2. Damage to cold spray due to excessive tool pressure, unless the adjacent material shows signs of lack of adhesion.

1.4.1.7.4. Document satisfactory machining test on reference (d).

1.4.1.8. Visual Inspection

1.4.1.8.1. Examine the finish machined mock-up with normal corrected vision without magnification.

1.4.1.8.2. Finish machined/ground cold spray shall be smooth, adherent, and free from visual voids, pits, cracks, and porosity.

1.4.1.8.3. Finish machined cold spray shall be 16 RHR or smoother.

1.4.1.8.4. All overspray shall be removed.

1.4.1.8.5. Termination (ends) of cold spray coating shall be smooth and fair with adjacent material.

1.4.1.9. Adhesion Testing, Ring

1.4.1.9.1. Lightly tap the cold spray coating with a ring tester and check for soundness (see reference (b) for standard ring tester). Ring tester shall be held lightly between two fingers. Excessive grip force will mute the ring and make differentiation between properly and poorly adhered cold spray difficult.

1.4.1.9.2. Inspect cold spray coating to the maximum extent practical.

1.4.1.10. Deliver Cold Spray Test Samples

1.4.1.10.1. Deliver bond buttons and mock-up per paragraphs 1.5.1 and 1.5.2, respectively.

1.4.1.10.2. Deliver a completed copy of reference (d) to PSNS. All blocks shall be completed, signed, and dated with the exception of bond and MEm data in block 18, and blocks 21 and 22. Badge number is not required for vendor personnel.

1.4.2. Cold Spray Repair Throttling Valve Tailpieces

1.4.2.1. General Requirements

1.4.2.1.1. Cold spray repair shall be accomplished using the qualified spray procedure (QSP, reference

(d)) developed in paragraph 1.4.1.

1.4.2.1.2. Requirements of this paragraph are written for 1 (ea.) valve tailpiece. A total of 4 (ea.) valve tailpieces require repair.

1.4.2.1.3. Where references to testing per paragraph 1.4, it shall be understood that references to the tailpiece mock-up will mean the shipboard component vice the mock-up used for testing.

1.4.2.1.4. 1 (ea.) cold spray application record (CSAR) is required for each repaired valve tailpiece.

Ensure CSAR is completed for each corresponding valve tailpiece (based on information in blocks 1 through 11 and shipping documentation) and is maintained with the component for traceability. Initiated CSAR forms are provided as references (e) through (g).

1.4.2.2. Prep Valve Tailpiece

1.4.2.2.1. Prep machine valve tailpiece per reference (d).

1.4.2.2.2. Prep surface for cold spray repair per reference (d).

1.4.2.2.3. Document part preparation in block 12 of reference (e), (f), or (g), as applicable.

1.4.2.3. Cold Spray Repair Valve Tailpiece

1.4.2.3.1. Cold spray repair valve tailpiece per reference (d).

1.4.2.3.2. Document repair in blocks 13 through 16 of reference (e), (f), or (g), as applicable.

1.4.2.4. Finish Machine Valve Tailpiece

1.4.2.4.1. Finish machine valve tailpiece per reference (a).

1.4.2.4.2. During and subsequent to machining, inspect cold spray coating per paragraph 1.4.1.7.

1.4.2.4.3. Measure and document finish machined tailpiece inside diameter in block 17 and machining adhesion test in block 18 of reference (e), (f), or (g), as applicable.

1.4.2.5. Testing

1.4.2.5.1. Accomplish visual inspection of cold spray coating per paragraph 1.4.1.8.

1.4.2.5.2. Accomplish ring test per paragraph 1.4.1.9.

1.4.2.5.3. Document test results in block 18 of reference (e), (f), or (g), as applicable.

1.4.2.6. Delivery

1.4.2.6.1. Deliver valve tailpiece and supporting CSAR (reference (e), (f), or (g), as applicable) to PSNS for review and acceptance of repair per paragraph 1.5.3.

1.5. Deliverable Items:

1.5.1. 7 (ea.) fixture bond buttons and 5 (ea.) substrate bond buttons.

1.5.2. 1 (ea.) throttling valve tailpiece mock-up, sectioned to allow inspection per MIL-STD-3021 paragraph 5.2.2 and 5.2.3.

1.5.3. 4 (ea.) throttling valve tailpieces cold spray repaired in accordance with paragraph 1.4.2.

1.5.4. 1 (ea.) completed QSP

1.5.5. Contractor-Furnished Material:

1.5.6. Contractor is responsible for furnishing all material required for testing associated with qualified spray procedure development per paragraph 1.4.2.

1.6. General Information

1.6.1. Quality Control The contractor shall develop and maintain an effective quality control program to ensure services are performed in accordance with this PWS. The contractor shall develop and implement procedures to identify, prevent, and ensure non-recurrence of defective services. The contractor’s quality control program is the means by which he assures himself that his work complies with the requirement of the contract. [Insert when and how the QCP is to be delivered, i.e., within 30 days after contract award or with the contractors proposal if it is an evaluation factor, three copies of a comprehensive written QCP shall be submitted to the KO and COR within 5 working days when changes are made thereafter.] After acceptance of the quality control plan the contractor shall receive the contracting officer’s acceptance in writing of any proposed change to his

QC system.

1.6.2. Quality Assurance: The government shall evaluate the contractor’s performance under this contract in accordance with the Quality Assurance Surveillance Plan. This plan is primarily focused on what the Government must do to ensure that the contractor has performed in accordance with the performance standards. It defines how the performance standards will be applied, the frequency of surveillance, and the minimum acceptable defect rate(s).

1.6.3. Recognized Holidays: Contractor is not required to perform services on holidays.

New Year’s Day Labor Day

Martin Luther King Jr.’s Birthday Columbus Day

President’s Day Veteran’s Day

Memorial Day Thanksgiving Day

Independence Day Christmas Day

1.6.4. Hours of Operation: The contractor is responsible for conducting business during their normal business hours.

1.6.5. Place of Performance: The work to be performed under this contract will be performed at

Contractor’s facility.

1.6.6. Type of Contract: The government will award a (Type of contract to be determined by CCE and the customer).

1.6.7. Special Qualifications: There are no special qualifications required for the work described in this performance work statement.

1.6.8. Post Award Conference/Periodic Progress Meetings: The Contractor agrees to attend any post award conference convened by the contracting activity or contract administration office in accordance with Federal Acquisition Regulation Subpart 42.5. The contracting officer, Contracting

Officers Representative (COR), and other Government personnel, as appropriate, may meet periodically with the contractor to review the contractor's performance. At these meetings the contracting officer will apprise the contractor of how the government views the contractor's performance and the contractor will apprise the Government of problems, if any, being experienced.

Appropriate action shall be taken to resolve outstanding issues. These meetings shall be at no additional cost to the government.

1.6.9. Contracting Officer Representative (COR): The (COR) will be identified by separate letter. The

COR monitors all technical aspects of the contract and assists in contract administration The COR is authorized to perform the following functions: assure that the Contractor performs the technical requirements of the contract: perform inspections necessary in connection with contract performance: maintain written and oral communications with the Contractor concerning technical aspects of the contract: issue written interpretations of technical requirements, including Government drawings, designs, specifications: monitor Contractor's performance and notifies both the

Contracting Officer and Contractor of any deficiencies; coordinate availability of government furnished property, and provide site entry of Contractor personnel. A letter of designation issued to the COR, a copy of which is sent to the Contractor, states the responsibilities and limitations of the

COR, especially with regard to changes in cost or price, estimates or changes in delivery dates. The

COR is not authorized to change any of the terms and conditions of the resulting order.

PART 3

GOVERNMENT FURNISHED PROPERTY, EQUIPMENT, AND SERVICES

3. Government Furnished Items And Services:

3.1. Services (If applicable): The Government will provide adhesion (bond) testing services and metallographic mock-up examination services.

3.2. Facilities (If applicable): Not applicable.

3.3. Utilities (If applicable): Not applicable.

3.4. Equipment (If applicable): Not applicable.

3.5. Materials (If applicable): The Government will provide 1 (ea.) valve tailpiece mock-up and 3 (ea.)

valve tailpieces.