Attachment 1 - DRAFT Performance Work Statement.pdf

PERFORMANCE WORK STATEMENT

FOR

ADDITIVE MANUFACTURING TO IMPROVE TEST AND EVALUATION OF

HYPERSONIC VEHICLES

Version 6

Prepared by

AEDC/TDH

1478 Fifth Street

Arnold AFB TN 37389

6 April 2022

TABLE OF CONTENTS

1 SCOPE

1.1 Background

2 APPLICABLE DOCUMENTS

3 CONTRACT ADMINISTRATION AND MANAGEMENT

3.1 Project Planning and Control

3.2 Project Reviews

4 TECHNICAL REQUIREMENTS

4.1 Development of Additive Manufacturing Capability

4.2 Application of Additive Manufacturing Capability

5 DELIVERABLES

6 SPECIAL REQUIREMENTS

6.1 Contractor Identification

6.2 Rights in Information and Data

6.3 Security Requirements

6.4 Associate Contractor Agreement (ACA)

1 SCOPE

This performance work statement (PWS) is for the development, analysis, and demonstration of a capability for using additive manufacturing (AM) to create advanced hypersonic test facility components and test articles for the Hypersonic Aerothermal and Propulsion Clean-Air Testbed

(HAPCAT) facility and other relevant Department of Defense (DoD) test facilities. The result of this effort will be a validated AM capability to support hypersonic ground testing.

1.1 Background

The DoD’s HAPCAT facility produces harsh conditions in order to simulate the environment a hypersonic vehicle will experience in flight. Given the extreme environment, components of the facility must withstand high temperatures and pressures, necessitating novel designs and manufacturing techniques. Similarly, test articles must also withstand such conditions. Certain materials that can survive the high temperature and pressure in this environment are usually required for facility components as well as test articles. Active cooling techniques, such as internal water passages, are also often needed in order to manage the thermal loading of the component. The use of exotic materials and active cooling techniques results in complicated and complex designs and manufacturing requirements for the facility components and test articles, which drive increased costs, schedules, and technical risks. New or improved techniques for designing and manufacturing facility components and test articles that reduce the cost, time, and technical risk would improve the DoD’s ability to conduct hypersonic ground testing at

HAPCAT and reduce flight test risk of hypersonic vehicle development. On-site support of an

AM capability would also provide the required support for rapid repairs and fabrications in a secure environment. This capability would also result in the ability to fabricate efficiently specialty test equipment specific to HAPCAT.

The AM capability for HAPCAT would have the additional benefit of supporting testing at other

DoD facilities that produce harsh conditions. These include, but are not limited to, the J-5 clean-air facility, the arc heater facilities, and the Aerodynamic and Propulsion Test Unit (APTU), all at the Arnold Engineering Development Complex (AEDC) at Arnold AFB, TN. Fabrication and repairs of facility components and test articles would be supported by this AM capability.

Technology development is required to develop and demonstrate the desired AM capability given the required application to HAPCAT and other DoD hypersonic facilities. The AM capability will provide reduced manufacturing times, increased facility availability, and improved support to DoD hypersonic weapon system ground test requirements.

2 APPLICABLE DOCUMENTS

N/A

3 CONTRACT ADMINISTRATION AND MANAGEMENT

3.1 Project Planning and Control

The contractor shall ensure performance of the business and administrative aspects of the contract.

The contractor shall identify a Project Manager (PM) to act as the single point of contact

(POC) responsible for managing and directing the contractor’s activities and that of its subcontractors with respect to this contract and for interfacing with the government.

Project management tasks include all those tasks required to direct and support production and program execution. The PM shall be responsible for all planning, organizing, scheduling, staffing, directing, controlling, orderly resource management, and reporting required in the execution of this contract.

The contractor shall ensure resources are efficiently and effectively managed and contract status (including Government-furnished resources) are reported to Government representatives.

The contractor shall maintain a qualified work force in sufficient numbers to manage, supervise, and perform all tasks required by this PWS and ensure compliance with all applicable regulations. The contractor shall conduct employee, supervisory, and management training programs if required in the performance of this effort.

The contractor shall develop and maintain a Project-level Integrated Master Schedule

(IMS) and associated work breakdown structure (WBS).

Deliverables:

A001, Integrated Master Schedule

A002, Work Breakdown Structure

The contractor shall provide a monthly status report to document technical progress made, schedule status, cost, and significant milestones.

Deliverable:

A003, Monthly Progress, Cost, and Status Report

3.2 Project Reviews

The contractor shall prepare and conduct an annual review meeting to brief the accomplishments; discuss major issues, concerns, and recommended solutions; and summarize the current financial status, including any projected shortfalls.

The contractor shall organize and conduct informal technical information exchange meetings (TIMs), normally held by phone or internet conferencing software acceptable to the Government. These TIMs will be used to discuss any progress, technical or financial issues; accomplishments; concerns; or other information the contractor deems important to bring to the Government’s attention. The TIMs shall be conducted on a monthly organized contact basis at a minimum with Government and / or its representatives, if deemed appropriate.

Deliverables:

A004, Records/Minutes of Meetings

A005, Presentation Materials for Meetings

4 TECHNICAL REQUIREMENTS

4.1 Development of Additive Manufacturing Capability

The first phase of this effort involves the development of HAPCAT facility components and test articles that leverage the unique attributes of AM. This requires research into the capabilities of

AM and how state-of-the-art designs for test facility components and test articles can be utilized that were previously unachievable due to manufacturing limitations. The end result will be AM infrastructure and an assessment of use cases that take advantage of AM capabilities for

HAPCAT.

The contractor shall develop an analysis of alternatives (AoA) for the development of a capability to utilize AM for producing prototype HAPCAT facility components and test articles. The AoA shall include an assessment of the current state-of-the-art AM capabilities and how they can be leveraged for producing the desired prototype components. The merits of AM capabilities, including cost, schedule, and performance parameters, shall be addressed. Consideration shall be given to the additive material capabilities and compatibilities required to ensure applicability to the material requirements for HAPCAT facility components and test articles. These materials include, but are not limited to, high temperature super alloys, oxygen-free high thermal conductivity (OFHC) Copper, GRCop-42, and GRCop-84. The AM capability shall also be capable of producing wall thicknesses and hole diameters of 0.050” +/- 0.005” in cooled components and building volumes of at least 1 ft^3. While the HAPCAT facility is the primary focus, such AM capability could also be applicable to other DoD hypersonic ground test facilities, and such consideration shall be included in the AoA.

A006, AoA Report

Based on the results of the AoA that capture the research performed on state-of-the-art

AM capabilities and the contractor’s recommendations, the contractor shall select an appropriate AM capability that addresses the requirements for producing prototype hypersonic test facility components and test articles outlined in Section 4.1.1. The contractor shall procure and install the selected AM capability, ancillary equipment, and required materials at the contractor’s facility. The contractor shall perform the appropriate site preparation to enable the installation of the AM capability and any associated equipment and material.

Deliverable:

The contractor shall outline how the AM capability can be utilized for the design and fabrication of HAPCAT facility components and test articles, taking advantage of the unique capabilities provided by AM. This assessment shall include appropriate use cases for facility components and test articles applicable to HAPCAT as well as the J-5 clean-air facility and arc heater facilities at AEDC. Such facility components include, but are not limited to, instrumentation rakes, direct connect inlet ducting and actively-cooled components. Test articles include, but are not limited to, high temperature wind tunnel models for blowdown and arc heater facilities, and other special aerothermal or aero-optical test apparatus. Appropriate research and development shall be performed to take advantage of the unique capabilities afforded by AM, and such conclusions shall be captured in the assessment. In addition to the identification of use cases for HAPCAT, the contractor shall consider and document in the assessment how such use cases could be extended to the J-5 clean-air facility and arc heater facilities at AEDC.

A006, Assessment of Use Cases

4.2 Application of Additive Manufacturing Capability

The second phase of this effort builds upon the research and development performed in the first phase. Based on the results of the assessment of use cases, the AM capability will be used to produce a facility component and tests article for evaluation. The end result will be a validated

AM capability to support HAPCAT operations and other test facilities for the DoD.

Using the Assessment of Use Cases from 4.1.3, the contractor shall design an instrumentation rake for installation in the HAPCAT facility and an aero-optical test apparatus for use in the HAPCAT facility. The contractor shall design the component and article to incorporate the unique capabilities afforded through AM. The contractor shall fabricate, inspect, and analyze the AM prototype components to assess their ability for use in hypersonic facilities. The results shall be summarized in a technical document that includes, but is not limited to, the following:

• Description of post-AM fabrication heat treatments.

• Dimension checks, tensile tests, and other inspections of the fabricated components.

• Results of any applicable hydrostatic pressure checks and flowrate checks.

• Comparisons of the prototype components to those fabricated using traditional methods, with the identification of improvements and advantages of AM compared to traditional methods.

A006, Assessment of Prototype Components

A007, Design of Components and Articles

The contractor shall integrate the facility component from 4.2.1 into the HAPCAT facility and evaluate the performance of the component through an operational test. The test plans for such testing shall be coordinated with the Government for approval. The contractor shall also install the selected test article manufactured via AM from 4.2.1 and evaluate the performance of the test article through an operational test The results of the testing and evaluation shall be summarized in a technical report. The technical report shall capture the work performed in 4.2.1 and 4.2.2. The technical report shall also include an assessment of how the designs of the components and test articles manufactured for HAPCAT could be extended for use in the J-5 facility.

A006, Assessment of AM Components

A008, Test Plans

The contractor shall use the knowledge gained from 4.2.1 and 4.2.2 to design and fabricate a demonstration test article for use in arc heater facilities. The contractor shall coordinate the test article design with the Government. The design shall incorporate the unique capabilities afforded through AM. The fabricated test article shall be analyzed to assess the ability for use in the arc heater facility. The fabricated test article shall be provided to the Government for testing in the arc heater facilities at AEDC. The

Government will provide arc heater facility interfaces and facilitate the installation of the article in the facility.

A006, Assessment of Arc Heater Facility Test Article

A007, Design of Arc Heater Facility Test Article

The contractor shall prepare a final engineering report detailing the methods used and issues discovered during the tasks performed in Phase 1 and Phase 2 (4.1 and 4.2) of this effort. The report shall include the following information:

• Findings of using various feedstock with the selected AM machine for the facilities supported.

• All results and findings from the operational checkouts performed in 4.2.2 and the design and fabrication of the arc heater test article developed in 4.2.3.

• Discussion of how the AM capability can best support facility operations at

HAPCAT, J-5, and the AEDC arc heater facility.

• Estimates of cost and schedule savings realized through the AM capability as compared to traditional methods.

• Recommendations based on the results of the studies for utilizing AM technology to support hypersonic ground test facilities.

A009, Final Technical Report

5 DELIVERABLES

Task Deliverable Data Item Description Data

Rights

4.2.2 Facility Components N/A N/A

4.2.2 Test Article N/A N/A

4.2.3 Demonstration Test Article N/A N/A

3.1.5 Integrated Master Schedule N/A Unlimited

3.1.5 Work Breakdown Structure DI-MGMT-81334D Unlimited

3.1.6 Monthly Progress, Cost, and Status Reports DI-MGMT-81928 NOT 1 Unlimited

3.2.2 Records / Minutes of Meetings DI-ADMN-81505 Unlimited

3.2.2 Presentation Materials for Meetings DI-ADMN-81373 Unlimited

4.1.1 Analysis of Alternatives Report DI-MISC-80508B Unlimited

4.1.3 Assessment of Use Cases DI-MISC-80508B Unlimited

4.2.1 Design of Components and Articles DI-SESS-81002F NOT 1 Unlimited

4.2.1 Assessment of Prototype Components DI-MISC-80508B Unlimited

4.2.2 Test Plans DI-NDTI-80566A Unlimited

4.2.2 Assessment of AM Components DI-MISC-80048 Unlimited

4.2.3 Design of Arc Heater Facility Test Article DI-SESS-81002F Unlimited

4.2.3 Assessment of Arc Heater Facility Test

Article

DI-MISC-80508B

Unlimited

4.2.4 Final Technical Report DI-MISC-80048 NOT 1 Unlimited

6 SPECIAL REQUIREMENTS

This section describes the special requirements for this effort. The following subparagraphs provide details of various considerations on this effort.

6.1 Contractor Identification

Contractor personnel and their subcontractors must identify themselves as Contractors or subcontractors during meetings, telephone conversations, in electronic messages, or correspondence related to this contract.

6.2 Rights in Information and Data

The contractor shall transfer ownership to the Government of all technical data, computer software, and computer software documentation as defined in DFARS 252.227-7013 and

252.227-7014 and all other data of any description or form, including all sketches, notebooks, designs, drawings, specifications, blueprints, models, negatives, photographs, findings, memoranda, reports, recommendations, automated data processing equipment

(ADPE) programs, as well as all copies of the foregoing, created, produced, developed, delivered, furnished, or provided under this contract, unless otherwise identified by the contractor as being furnished with Government purpose rights, limited rights, or restricted rights. Except for technical data, computer software, or computer software documentation identified by the Contractor as being furnished with Government purpose rights, limited rights, or restricted rights, the contractor retains no right, title, or interest in and to such data, computer software, and computer software documentation which becomes the property of the Government. This property shall be delivered by the contractor to the Government upon completion or termination of this contract or when directed by the Contracting Officer. The Government reserves its right to take delivery of this data, computer software, and computer software documentation via Contract Data

Requirements Lists (CDRLs) or as deferred delivery at the point the Government chooses. As owner, the Government may use, reproduce, or disclose the data, computer software, and computer software documentation covered by this requirement in any way and for any purpose it may desire with the exception that competition sensitive data, marked as such by the contractor and so agreed to by the Government, such as personal data on individuals, payroll records, management methodology, and organizational approaches, shall not be disclosed outside the Government. The contractor shall mark the number of this contract on all data, computer software, and computer software documentation delivered hereunder. Any data, computer software, or computer software documentation belonging to third parties and furnished to the contractor by the

Government in performance of this contract shall be treated as property of the

Government.

Except as specifically authorized by this contract, or as otherwise approved in writing by the Contracting Officer, all information and data furnished by the Government to the contractor in the performance of this contract shall be used only in connection with the work under this contract and shall be protected by the contractor from unauthorized use, release, duplication, or disclosure.

The contractor shall take appropriate measures to assure that its personnel, who have or might reasonably have access to such information and data referred to in paragraph (b) above, agree to honor the contractor's commitment and safeguard such information and data.

If the contractor acquires technical or other data, computer software, or computer software documentation necessary for the performance of this contract from any third party through license or otherwise, in addition to providing the Government with rights or title to such data, computer software, and computer software documentation in accordance with subparagraph (a) of this clause, the contractor shall also obtain all rights necessary to allow such rights in data, computer software, and computer software documentation to be assigned to any successor contractor to this contract.

6.3 Security Requirements

The contractor shall comply with all security directives and other security requirements identified in this document.

Department of Defense (DoD) Credentials:

6.3.1.1 The contractor shall ensure base access and circulation control credentials required for contract performance are obtained for all employees. The contractor shall retrieve all identification media upon completion or termination of the contract and from employees who depart for any reason before the contract expires, e.g., the employee quits, is terminated, retires, etc.

6.3.1.2 The contactor shall immediately notify the issuing office for an appropriate update in the information system of record when a contractor employee refuses to return issued access media. If a local access credential is not returned, the Installation Commander may consider debarring the individual. All contractor personnel must immediately report a lost or stolen access credential to the local issuing office, so the card can be updated as lost / stolen in the system of record.

6.3.1.3 The contractor shall comply with all installation access requirements as directed in

DoDM-5200.08_Volume 3_AFMAN 31-101_Volume 3, Installation Perimeter Access

Control, as supplemented, and AAFB 31-101, Integrated Defense Plan. The Arnold

Engineering Development Complex Commander (AEDC/CC) reserves the right to refuse entry and / or re-entry of any person to Arnold AFB for just cause to protect personnel, facilities, and property under his / her control when such actions are deemed necessary.

6.3.1.4 All persons performing on the contract will be required to provide documents to positively prove their identity prior to being vetting for base entry. Identification must be compliant with the REAL ID Act of 2005. Individuals who do not possess a driver’s license or identification card compliant with the REAL ID Act and do not possess an acceptable alternate identification credential, must be escorted or denied access.

Freedom of Information Act (FOIA): The contractor shall comply with FOIA policy and procedures for the disclosure of records to the public and for marking requirements in accordance with DODM 5400.7, DoD Freedom of Information (FOIA) Program, Chapter

4. This regulation, handling, transmitting, and safeguarding Controlled Unclassified

Information (CUI) material.

Controlled Unclassified Information (CUI)

6.3.3.1 CUI shall be safeguarded as specified in DoDI 5200.48_DAFI 16-1403: Controlled

Unclassified Information (CUI). This may include information with legacy For Official

Use Only (FOUO) markings, previously protected under DoDM 5200.01-V4, DoD

Information Security Program: Controlled Unclassified Information. Sensitive information is information that if lost, misused, compromised or accessed by unauthorized personnel could adversely affect U.S. national interest, the conduct of

DoD programs, or the privacy of DoD personnel. It comes in many forms; personal data under the Privacy Act, personnel records, privileged data (chaplain and judge advocate records), investigative data, scientific and technical information (STINFO), export-controlled data (critical technologies), proprietary data, or other CUI data. For general CUI guidance, contact AEDC/IP at (931) 454-3290.

6.3.3.2 If access to CUI / Export Control / STINFO information is required, the contractor shall be required to be registered as a certified Government contractor through the Joint

Certification Office, Defense Logistics Information Service (DLIS). To request DLIS

Certification, submit a DD Form 2345, Militarily Critical Technical Data Agreement, to the DLIS, Battle Creek MI address indicated at the top of the DD Form 2345 along with a copy of the company's state business license, incorporation certificate, sales tax identification form, or other documentation, which verifies the legitimacy of the company. A copy of the contractor’s DD2345, Militarily Critical Technical Data

Agreement, must be provided when issued. Except as allowed by DFARS 252.225-

7048, Export-Controlled Items, foreign nationals shall not have access to export-controlled information without an export license. All export-control laws as stipulated in both Export Administration Regulation and International Traffic in Arms Regulation must be followed without exception. For guidance in applying appropriate export-control markings, contact AEDC/IP at (931) 454-4243.

6.3.3.3 The contractor must obtain Foreign Disclosure Office (FDO) approval through the

Contracting Officer prior to allowing any non-US or un-validated U.S. Lawful

Permanent Resident person’s access to CUI or export-controlled information. (Also, see

DFARS 252.225-7048).

Reporting Requirements: Contractor personnel shall report to an appropriate authority any information or circumstances of which they are aware that may pose a threat to the security of DoD personnel, contractor personnel, resources, and classified or unclassified defense information. Contractor employees shall be briefed of this requirement by their immediate supervisor upon initial on-base assignment.

Information Security (INFOSEC): Information, regardless of media, shall be controlled and maintained in accordance with (IAW) with the National Industrial Security Program

Operating Manual (NISPOM).

Operations Security (OPSEC): The contractor shall:

6.3.6.1 Integrate OPSEC into all planning and operational processes.

6.3.6.2 Integrate OPSEC into all contractor support documents.

6.3.6.3 Implement OPSEC programs for subcontractors designed to afford at least a minimum level of OPSEC protection and understanding for all subcontracts with increasing levels of OPSEC protection and understanding for more sensitive subcontracts, recognizing that subcontractors vary in size, resources, and length of subcontract.

6.3.6.4 Contractor employees must complete Level I OPSEC Awareness training. New employees must be trained within 30 calendar days of their reporting for duty and annually thereafter.

Anti-terrorism (AT) Training: All DoD contractor employees shall complete annual

Level 1 AT Awareness Training. This training can be accessed through the Advanced

Distributed Learning Services (ADLS) at https://golearn.adls.af.mil/login.aspx.

Contractor Consent to Background Checks: The Contractor shall not employ persons to perform under this contract if such employee is deemed or identified as a potential threat to the health, safety, security, general well-being, or mission of its operational location and population.

6.3.8.1 Contractors must ensure their employees and those of their subcontracts have the proper credentials allowing them to work in the United States. Persons later found to be undocumented or illegal aliens will be remanded to the proper authorities.

6.3.8.2 The Contractor shall not be entitled to any compensation for delays or expenses associated with complying with the provisions of this clause. Furthermore, nothing in this clause shall excuse the Contractor from proceeding with the contract as required.

6.4 Associate Contractor Agreement (ACA)

The contractor shall establish ACAs and/or Non-disclosure Agreements (NDAs) with other agencies as necessary to allow sharing of program information with third party organizations.

Any data shared will be in accordance with the terms of the applicable ACA and/or NDA, including the provisions for data rights specified in the contract. Sharing of information may include attendance at meetings and teleconferences with third party contractors or other

Government activities. The contractor shall enter into ACAs in a timely manner to avoid delays in tasks related to this contract. All ACAs shall be submitted to the Contracting Officer within

30 calendar days of execution.