A04.01 Cold Spray PWS.pdf

PERFORMANCE WORK STATEMENT (PWS)

COLD SPRAY REPAIR OF THROTTLING VALVE BODY & TAILPIECE

1. GENERAL: This is a non-personnel services contract to provide cold spray repair of up to 3 (ea.)

MCW throttling valve bodies and tailpieces. 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 cold spray repair of the throttling valve bodies and tailpieces 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 cold spray repair of up to 3 (ea.) throttling valve bodies, pc-12 of reference (a) & up to 3 (ea.) throttling valve tailpieces, pc-7 of reference (a).

1.2.1. Details of cold spray bond buttons and ring tester are shown in reference (b).

1.2.2. Throttling valve body is approximately 7-3/4” tall, 16-3/4” in diameter, made from Copper-Nickel

70-30. Repair area is approximately .06” deep, 6-1/2” long, on a 12” inside diameter. See reference

(c) for spray location and details.

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.

1.2.3. Period of Performance (POP): January 25, 2021 to March 5, 2021

1.3. Objectives:

1.3.1. Cold spray repair up to 3 (ea.) throttling valve bodies and tailpieces per Qualified Spray Procedure

(QSP) 4674165.12.02.S.

1.4. Scope: Services include manufacture, cold spray, and testing of test specimens and cold spray and inspection of a mock-up, if required. Services also include cold spray repair of up to 3 (ea.) throttling valve bodies and tailpieces. The contractor shall accomplish the following.

1.4.1. References

(a) NAVSEA drawing 4674165 rev B Excerpt

(b) Qualified Spray Procedure Test Coupon Details

(c) Body, PC-12, Cold Spray Mockup, Code 260M sketch [PC-12 body mockup.dft]

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

(e) QSP-4674165.12.02.S.pdf

(f) CSAR-MOCKUP-0001.pdf

(g) CSAR-MOCKUP-0002.pdf

(h) CSAR-LAC-0001.pdf (MCW-5)

(i) CSAR-LAC-0002.pdf (MCW-5)

(j) CSAR-LAC-0005.pdf (MCW-7)

(k) CSAR-LAC-0006.pdf (MCW-7)

(l) CSAR-LAC-0007.pdf (MCW-8)

(m) CSAR-LAC-0008.pdf (MCW-8)

1.4.2. General Requirements

1.4.2.1. References to the qualified spray procedure (QSP) refer to reference (d), QSP 4674165.12.02.S.

1.4.2.2. If a successful cold spray repair has been completed per the QSP within one calendar year of the contract award date, as verified by the application data signature on the most recently completed cold spray application record (CSAR), mock-up and adhesion testing (bond buttons) may be omitted.

1.4.2.3. Cold spray shall be accomplished per the applicable qualified spray procedure (QSP). All critical parameters (denoted on the QSP) shall be met. Deviation from critical parameters on the QSP is not allowed.

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

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

1.4.2.6. Requirements of the final part cold spray repairs are written for 1 (ea.) valve body. A total of up to 3 (ea.) valve bodies require repair.

1.4.2.7. During final part cold spray repair, where references to testing per paragraph 1.4.5 through 1.4.7, it shall be understood that references to the body mock-up will mean the shipboard component vice the mock-up used for testing.

1.4.2.8. 1 (ea.) cold spray application record (CSAR) is required for each repaired valve body. Ensure

CSAR is completed for each corresponding valve body (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 (f) through (i).

1.4.3. Adhesion Testing, Bond

1.4.3.1. Adhesion testing 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.

1.4.3.2. 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.

1.4.3.3. 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”.

1.4.3.4. Deliver bond buttons to PSNS per paragraph 1.5.1.

1.4.4. Metallographic Mock-Up Testing

1.4.4.1. Mock-up will be inspected by the PSNS laboratory. Mock-up may be examined or paragraph

1.4.4.7 omitted at the vendor’s discretion. Acceptance criteria is per paragraph 1.4.4.8.

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

1.4.4.3. Prep and cold spray 1 (ea.) throttling valve body and tailpiece mock-up. Ensure sufficient build up is applied to finish machine mock-up inside diameter to a final size of 11.974” to 11.978”.

1.4.4.4. Finish machine mock-up per reference (a). Inspect mock-up during and subsequent to machining per paragraph 1.4.5 Ensure all overspray is removed. Measure and document final mock-up inside diameter in block 17 of reference (e).

1.4.4.5. Accomplish visual inspection per paragraph 1.4.6.

1.4.4.6. Accomplish ring testing per paragraph 1.4.7.

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

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

1.4.4.9. Acceptance criteria is 3% maximum oxides and 2% maximum porosity. The QSP specifies a duplex Chrome-Carbide Nickel powder. Chrome-carbide shall not be considered an oxide per this requirement.

1.4.4.10. There shall be no evidence of classification (significant changes in powder ratios through thickness of spray) of the duplex powder.

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

1.4.5. Adhesion Testing, Machining

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

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

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

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

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

1.4.5.4. Document satisfactory machining test on reference (e).

1.4.6. Visual Inspection

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

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

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

1.4.6.4. All overspray shall be removed.

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

1.4.6.6. Document satisfactory visual inspection on reference (e).

1.4.7. Adhesion Testing, Ring

1.4.7.1. 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.

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

1.4.7.3. Document satisfactory ring test on reference (e).

1.4.8. Deliver Cold Spray Test Samples

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

1.4.8.2. Deliver a completed copy of reference (e) to PSNS. All blocks shall be completed, signed, and dated with the exception of bond and metallographic mock-up data signatures in block 19, and blocks 20 and 21. Badge number is not required for vendor personnel.

1.4.9. Prep Valve Body and Tailpiece

1.4.9.1. Prep surface for cold spray repair per QSP.

1.4.9.2. Document part preparation in block 12 of CSAR.

1.4.10. Inspect and Repair Defects (pre-repair)

1.4.10.1. Visually inspect body ID for pitting or other defects that will potentially propogate through the final cold spray coating. If no defects are found, no local defect repair is required.

1.4.10.2. Hand grind defects to establish a 4 to 1 diameter to depth ratio with a fully radiused bottom. Do not violate minimum wall thickness of .361”. Notify PSNS if defects do not clear within allowed grind limit.

1.4.10.3. Visually inspect tailpiece sealing surface for pitting or other defects that will potentially propogate through the final cold spray coating. If no defects are found, no local defect repair is required.

1.4.10.4. Hand grind defects to establish a 4 to 1 diameter to depth ratio with a fully radiused bottom. Do not violate maximum grind-out depth of .100” (from finished surface). Notify PSNS if defects do not clear within allowed grind limit.

1.4.10.5. Cold spray repair (hand spray) local defects per QSP. Document cold spray repair in CSAR block 16 with a note that cold spray was applied to repair local defects prior to bulk application.

1.4.10.6. Hand grind or machine cold spray coating smooth and fair with prepped body ID.

1.4.11. Cold Spray Repair Valve Body

1.4.11.1. Cold spray repair valve body per QSP. Ensure sufficient material is deposited to finish machine valve body ID per reference (a) (11.974” / 11.978” diameter). Cold spray repair valve tailpiece per

QSP.

1.4.11.2. Document repair in blocks 13 through 16 of CSAR.

1.4.12. Inspect and Repair Defects (post-repair)

1.4.12.1. Visually inspect cold spray coating for pitting or other defects that will not be completely removed with final machining. If no defects are found, no further action required.

1.4.12.2. Hand grind valve body defects to establish a 4 to 1 diameter to depth ratio with a fully radiused bottom. If defects propogate through coating and into base metal, do not violate minimum base metal wall thickness of .361”. Notify PSNS if defects do not clear within allowed grind limit.

1.4.12.3. Hand grind tailpiece defects to establish a 4 to 1 diameter to depth ratio with a fully radiused bottom. If defects propogate through coating and into base metal, do not violate maximum grind-out depth of .100” (from finished surface). Notify PSNS if defects do not clear within allowed grind limit.

1.4.12.4. Cold spray repair (hand spray) local defects per QSP. Document cold spray repair in CSAR block 16 with a note that cold spray was applied to repair local defects after bulk application.

1.4.13. Delivery

1.4.13.1. Deliver valve body and supporting CSAR to PSNS for review and acceptance of repair.

1.5. Deliverable Items:

1.5.1. 7 (ea.) fixture bond buttons and 5 (ea.) substrate bond buttons, if required (see 1.4.2.2).

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

3021 paragraph 5.2.2 and 5.2.3, if required (see 1.4.2.2).

1.5.3. Up to 3 (ea.) throttling valve bodies and tailpieces cold spray repaired in accordance with QSP.

1.5.4. Contractor-Furnished Material:

1.5.5. Except as noted, contractor is responsible for furnishing all material required for testing per paragraph 1.4.

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. 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 Firm Fix Price contract.

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 body mock-up and 3 (ea.)

valve bodies.