AFNWC - SUU-72 Pylon Upper Panel Replacement including Refurb - Request for Information.pdf

Request for Information

Regarding

Suspension Underwing Unit (SUU) – 72 Pylon: Upper Panel Replacement, Including General Refurbishment, and

Pylon Load Adaptor (PLA): Refurbishment with New Walkways

17 September 2024

Request for Information

Regarding

Suspension Underwing Unit – 72 (SUU-72): Upper Panel Replacement, Including General Refurbishment, Pylon Load Adaptor (PLA): Refurbishment with New Walkways

Overview: The US Air Force, through the Air Force Nuclear Weapons Center, Nuclear Weapons Acquisition Division at Eglin AFB (AFNWC/NDB) is developing Bomber Weapon Interface Equipment (BWIE) in support of the Long Range Standoff (LRSO) Cruise Missile (CM) integration on the B-52 weapon system. There is a requirement to:

a. Refurbish SUU-72 Pylons.

b. Refurbish ADU-490A/E Pylon Load Adaptors (PLAs).

c. Build new PLA Walkways.

d. Build spare parts for SUU-72s and PLAs.

Background: SUU-72 Pylons have been in desert storage for many years using PLAs as cradles.

Long-term environmental exposure has resulted in corrosion damage to both Pylons and PLAs.

Repair of damage must be performed before hardware is modified to a SUU-103 configuration.

Corrosion damage is primarily focused on the Upper Panel, an aluminum bulkhead in the Pylon’s basic structure. Due to the type of corrosion, Upper Panels are planned to be replaced under this effort. The existing bulkhead aluminum alloy material is no longer acceptable for use on US Air Force weapons systems. A replacement alloy needs to be identified, replacement bulkheads manufactured, and installed in the Pylons. The PLAs are made of steel and some parts in the swing arm mechanism are rusted or missing. PLA frames are in a rusted but repairable condition. Any other corroded, damaged, or missing parts in the Pylon or PLA will require repair or replacement. New PLA Walkway assemblies, (Right and Left assemblies per PLA) are needed.

Purpose: AFNWC/NDB is seeking information from industry regarding a wholistic solution to the PLA/Pylon refurbishment and fabrication of new PLA Walkways. The solution shall be all encompassing to include receiving the Pylons and PLAs from storage, corrosion mitigation, manufacture and replacement of the SUU-72 Pylon upper panels, restoration of the Pylon to a flightworthy condition and refurbishment of PLAs to condition Code A. All hardware is intended to meet a minimum 30-year service life. Once refurbishment is complete, the SUU-72 will be inducted into a modification line and converted into a SUU-103. The modification production line requires 9 refurbished Pylons and PLAs ready for induction no later than December 2028.

There will be a requirement for additional quantities of at least 9 per year following the initial delivery for a total of 43.

Scope of Effort: The Pylons will be delivered to the awarded contractor mounted on PLAs. A summary of the effort is as follows:

a. Using MIL-STD-1587E, Material and Process Requirements for Aerospace Weapon Systems, identify a suitable material to replace the current SUU-72 aluminum alloy 2024 T3 Upper Panels as a Form-Fit-Function replacement.

b. Fabrication and validation of critical tooling. See Attachment 1—Drawing FAJ361-11434- 998, Upper Panel Assy Jig for historical reference. We believe this jig was used to originally manufacture the Pylons. Technical Orders indicate that this jig was used for replacement of Upper Panels, but new tooling may be used if designed for this purpose by the awarded contractor.

c. Prepare Pylon for Upper Panel replacement per Attachment 2 – Reference Technical Order (T.O.) 16W6-33-1 SUU-67* Operation & Maintenance Instructions, and Attachment 8 – 16W6-33-13, Overhaul Instructions.

d. Removal of the Upper Panel using historic alignment jig OR re-designed tooling.

e. In addition to the Upper Panel, inspect entire Pylon using Attachment 2 – Reference T.O.

16W-33-1, SUU-67* Operation and Maintenance, repair or replace and missing, damaged, or corroded parts. Pylon weapon fairings (6 each) are NOT to be included in this effort because these will be modified later. Pylon drawings and associated parts lists will be provided as needed.

f. Fabrication and installation of a new Upper Panel using the following technical data:

- Attachment 2 – Reference T.O. 16W6-33-1, O&M Instructions

- Attachment 3 –361-11375, Panel - Upper, Pylon STA 127.5-426.0

- Attachment 4 – PL361-11375, Parts List Panel - Upper, Pylon STA 127.5-426.0

- Attachment 5 –361-11374, Panel Instl – Upper Pylon STA 127.5-426.0

- Attachment 6 –PL361-11374, Parts List Panel Instl – Upper Pylon STA 127.5- 426.0

- Attachment 7 –Reference T.O. 16W6-33-4 SUU-67* Illustrated Part Breakdown

- Attachment 8 – Reference T.O. 16W6-33-13 SUU-67* Overhaul Instructions

* These T.O.s also apply to the SUU-72. The main body (to include the Upper Panel) of the SUU-67 Pylon is identical to the SUU-72. The SUU-72 is a modified SUU-67. The modification consisted of fairing changes.

g. Re-assemble Pylon per Attachments 2 and 8.

h. Complete Flight Qualification/Airworthiness Certification of replacement effort is required and will be coordinated with AFNWC/NDB.

i. Deliver an updated nonproprietary Technical Data Package (TDP) for all associated tooling (i.e. jigs/fixtures/molds/piece parts) related to the replacement of the Upper Panel since original manufacture drawings are provided for reference only.

j. Refurbish PLAs using Attachment 11 – Reference T.O. 11N-H5066-2, Operation and Maintenance with Parts Breakdown and Attachment 12 – F361-11706 Adaptor – Pylon Loader.

k. Build new PLA Walkway assemblies (Right and Left Assy per PLA) using drawings in

Attachment 12.

l. Store approximately four (4) assembled SUU-72 Pylons/PLAs during the development period. Additionally, be able to store refurbished Pylons/PLAs awaiting shipment to SUU- 103 modification line.

Technical Characteristics: Figure 1 shows a fully assembled SUU-72 Pylon.

Figure 1. Fully Assembled SUU-72 Pylon

The footprint of the SUU-72/ Pylon Loaded Adapter (PLA) assembly is relatively large. The footprint of the assembly is 40’ L X 11’6”H X 10’6” W. The weight of the assembly is 11,500 lbs.

(Pylon – 4,500 lbs., PLA – 7,000 lbs.). Figure 2 contains a photo of a Pylon mounted on a PLA.

Upper Panel

Figure 2. SUU-72 Mounted on a PLA w/o Walkways

Critical alignment tooling (historical reference - critical alignment jig) will be needed to secure the Pylon for Upper Panel removal and replacement. Attachment 1—Drawing FAJ361-11434- 998, Upper Panel Assy Jig is being supplied as a historical reference regarding the design and use of the jig(s). There are no known jig(s) in existence so alignment tooling must be fabricated.

Additional jig drawings for the Pylon side plates and swing arm are included for information purposes only as Attachment 9 – Drawing FAJ361-11297, Side Panel Jig and Attachment 10 – Drawing FAJ361-11417, Swing Arm Jig. Offerors should have experience in designing, building, validating, and use of similar aircraft tooling.

The existing Upper Panel is a 25’L X 1’8” W one-piece machined aluminum alloy (2024 T3) part.

The Upper Panel is attached to the Basic Structural Assembly using numerous fasteners. Some of the fasteners will be corroded. Offerors should have experience with the removal, fabrication, and installation of aircraft parts of a similar size and complexity. The machining drawing and installation of the Upper Panel is included in this data package as Attachments 3, 4, 5, and 6. Other drawings will be provided upon request. Figures 3a and 3b show typical fasteners used to secure the Upper Panel.

Figure 3a. Typical Upper Panel Fasteners

Fasteners

Figure 3b. Typical Upper Panel Fasteners

The PLAs will be refurbished using Attachment 11 – Reference T.O. 11N-H5066-2 Operation and Maintenance with Parts Breakdown and Attachment 12 – F361-11706 Adaptor– Pylon Loader.

Drawing F361-11706 is the assembly drawing for the entire PLA, including the Walkway assemblies. Most of the PLA primary structure and swing arm housings are in relatively good condition with minor rust. The internal swing arm mechanism parts may require replacement.

A few external parts associated with the swing arm and swing arm locking mechanism may be missing and will require replacement. Figure 4 contains a snip of a 3D PLA assembly model.

Attachment 13 – ADU-490_assy.stp contains an unvalidated 3D reference model of an ADU- 490/E. NOTE: This effort involves a refurbishment and new Walkways for ADU-490A/Es. The only difference between an ADU-490A/E and an ADU-490/E is the swing arm assembly.

Figure 4. PLA Assembly with Walkways

Requested Information:

The information requested below is to assess overall Industry capability available in the market to meet the AFNWC/NDB requirements.

Fasteners

a. What capability would be necessary to manufacture the necessary tooling required to complete this task?

b. What capability would be necessary to manufacture large (i.e. 25 feet long) machined/milled/heat treated aluminum structures?

c. What experience is recommended to complete a task such as this?

d. What experience would be necessary with developing a technical data package with limited source data?

e. What is your company’s experience with Air Force Air Worthiness requirements and ground and flight testing?

f. What is your estimated schedule to deliver a fully refurbished Pylon?

g. What would be required to ramp-up the refurbishment effort to produce at least 10 Pylons to a structurally flightworthy condition and PLAs to condition “A” per year, no later than December 2028? How much risk to meet this schedule?

h. What would be your estimated level of effort (hours) and facilities required to complete this effort. Would you be willing to provide a RoM cost?

i. Do you have any other creative solutions to solve this problem? What approach would you recommend ensuring an optimal strategy for the Government?

j. Please provide your interest in this effort and whether you would provide an offer as a prime or as a subcontractor.

k. Would your interest in the effort change should the Government request Unlimited Rights for the Technical Data Package?

l. Please provide any Multiple Award Contract(s), or Indefinite Delivery Indefinite Quantity contracts, you are currently on-boarded onto.

RESPONSE GUIDELINES:

All interested vendors shall submit a capabilities statement that explicitly demonstrates their capability to provide/perform the requirement stated in this notice. The capabilities statement should be brief and concise, yet clearly demonstrate an ability to meet the stated requirement.

The response must not exceed 15 pages, single side. Submissions shall be single spaced, 12-point type with at least one-inch margins on 8 ½” X 11” page size. Oral communications are not permissible.

Responses should include the following information with response:

1. Business Name and Address

2. Name of company representative and business title

3. Email for individual to receive DoD SAFE files containing Military Critical Technical Data.

4. Cage Code and Data Universal Number system (DUNS) number

5. Copy of your company’s approved DD Form 2345, Military Critical Technical Data

Agreement.

Businesses with only partial capabilities of this requirement are encouraged to submit a capabilities statement demonstrating the portion of the requirement they can provide/perform.

This information will allow the Government to identify areas of possible breakout or possible subcontracting opportunities.

Responses may be submitted electronically to the following e-mail addresses:

alyssa.hurst@us.af.mil. All correspondence sent via email shall contain a subject line that reads " SUU-72: Upper Panel Replacement, Including General Refurbishment " If this subject line is not included, the e-mail may not get through e-mail filters at Eglin AFB. Filters are designed to delete emails without a subject or with a suspicious subject or attachment. Attachments with files ending in .zip or .exe are not allowable and will be deleted. Ensure only .pdf, .docx, or .xlsx documents are attached to your email. All other attachments may be deleted. Please contact the POCs if a DoD Safe Link is required to submit your Request for Information response.

All responsible sources may submit information that shall be considered by the agency. If late information is received, it may be considered, depending on agency time constraints. All routine communications regarding the announcement should be directed to the contractual point of contact listed in this posting. The Government may or may not use any responses to this Request for Information as a basis for a subsequent project/requirement. Responses to this Request for Information will not be returned. The Government is under no obligation to acknowledge receipt of the information received or provide feedback to the respondents with respect to any of the information submitted under this Request for Information. No requests for a bid package or solicitation will be accepted; a bid package or solicitation does not exist at this time. In order to protect the integrity of any possible future acquisition, no additional information will be provided and no appointments for presentations will be made in reference to this Request for Information.

Government employees will review submitted responses to this Request for Information.

Respondents are advised that employees of commercial firms under contract with the Government may be used to review submissions and perform technical assessments requiring access to other contractor's proprietary information. These support contractors are bound by nondisclosure agreements prohibiting their contractor employees from disclosing any information submitted by other contractors or using such information for any purpose other than that for which it was furnished.

INDUSTRY DISCUSSIONS:

US Air Force representatives may choose to meet with potential offerors and hold one-on-one discussions. Such discussions would only be intended to obtain further clarification of potential capability to meet the requirements, including any development and certification risks.

QUESTIONS:

Questions regarding this Notice shall be submitted by e-mail to alyssa.hurst@us.af.mil no later than 4:00 P.M. (CST) on 26 September 2024. Questions by any other medium will NOT be accepted. The Government will not reimburse companies for any costs associated with the submissions of their responses.

DISCLAIMER:

This Request for Information is issued solely for information and planning purposes. This notice is not an RFP and is not to be construed as a commitment by the Government to issue a solicitation or ultimately award a contract. Responses will neither be considered as proposals, nor will any award be made as a result of this Request for Information.

All information contained in the Notice is preliminary as well as subject to modification and is in no way binding on the Government. FAR clause 52.215-3, "Request for Information or Solicitation for Planning Purposes," is incorporated by reference in this Request for Information. The Government does not intend to pay for information received in response to this Request for Information. Responders to this invitation are solely responsible for all expenses associated with responding to this Request for Information. This Request for Information will be the basis for collecting information on capabilities available. This Request for Information is issued solely for information and planning purposes. Proprietary information and trade secrets, if any, must be clearly marked on all materials. All information received in this Request for Information that is marked "Proprietary" will be handled accordingly. Please be advised that all submissions become Government property and will not be returned nor will receipt be confirmed. In accordance with FAR 15.201(e), responses to this Request for Information are not offers and cannot be accepted by the Government to form a binding contract.

All government and contractor personnel reviewing Request for Information responses will have signed non-disclosure agreements and understand their responsibility for proper use and protection from unauthorized disclosure of proprietary information as described 41 USC 423. The Government shall not be held liable for any damages incurred if proprietary information is not properly identified.

An AFNWC Ombudsman has been appointed to consider and facilitate the resolution of concerns for this acquisition. Before consulting the Ombudsman concerned parties should first address their concerns, issues, disagreements, and/or recommendation to the Contracting Officer for resolution. In addition, IAW AFFARS 5352.201-9101, The Ombudsman Information, will be included. The AFNWC Ombudsman can be contacted at:

Ms. Stephanie Gisseman stephanie.gisseman@us.af.mil

(478) 714-8398 mailto:alyssa.hurst@us.af.mil mailto:stephanie.gisseman@us.af.mil

RESPONSES ARE DUE NO LATER THAN 4:00 P.M. (CST) O 30 October 2024. Direct all questions concerning this requirement to Capt Alyssa Hurst at alyssa.hurst@us.af.mil no later than 4:00 P.M.

(CST) on 26 September 2024.

Attachments:

*Attachments will be provided upon request to interested parties. Please submit the following information to Capt Alyssa Hurst at alyssa.hurst@us.af.mil and Mr. Randy Hoffman at randy.hoffman.3@us.af.mil with the subject line " SUU-72: Upper Panel Replacement, Including General Refurbishment: Data Request”:

1. Business Name and Address

2. Name of company representative and business title

3. Email for individual to receive DoD SAFE files containing Military Critical Technical Data.

4. Cage Code and Data Universal Number system (DUNS) number

5. Copy of your company’s approved DD Form 2345, Military Critical Technical Data

Agreement.

Upon verification of the entity’s identity, Attachments 1-13 will be sent through DoD SAFE.

Attachment 1 - Drawing FAJ361-11434-998, Upper Panel Assy Jig Attachment 2 - Reference Technical Order 16W6-33-1 SUU-67 O&M Instructions Attachment 3 - 361-11375, Panel – Upper, Pylon STA 127.5-426.0 Attachment 4 - PL361-11375, Parts List Panel - Upper, Pylon STA 127.5-426.0 Attachment 5 - 361-11374, Panel Instl – Upper Pylon STA 127.5-426.0 Attachment 6 - PL361-11374, Parts List Panel Instl – Upper Pylon STA 127.5- 426.0 Attachment 7 - Reference T.O. 16W6-33-4 SUU-67 Illustrated Parts Breakdown Attachment 8 - Reference T.O. 16W6-33-13 SUU-67 Overhaul Instructions Attachment 9 - Drawing FAJ361-11297, Side Panel Jig Attachment 10 - Drawing FAJ361-11417, Swing Arm Jig Attachment 11 - Reference Technical Order 11N-H5066-2, Operation and Maintenance with Parts Breakdown Attachment 12 - F361-11706 Adaptor – Pylon Loader Attachment 13 - ADU-490_assy.stp

Enclosures:

Enclosure A: DD Form 2345 mailto:randy.hoffman.3@us.af.mil