MAST_BAA_Calls_2 3 4_Technical_Requirements.docx

POTENTIAL TECHNICAL REQUIRMENTS FOR CALL 2, 3, AND 4 OF BROAD AGENCY ANNOUNCEMENT

BAA-RQR-2014-0002

22 Jan 2014

Distribution A: Approved for public release; distribution unlimited.

Public Affairs Clearance Number 14018 1.

CALL 2 DESCRIPTION

RP21 2017 A&S Goal Demonstration Requirements:

Technology Demonstration Objective: Demonstrate RP21 Aging & Surveillance (A&S) 2017 goal achievement (reduce the predictive uncertainty of the service life estimate by 20%), with negligible impact to other RP21 goals.

All technology demonstration efforts shall:

Verify experimentally the RP21 A&S technology baseline Demonstrate the RP21 A&S 2017 goal, utilizing a concrete and verifiable non-proprietary methodology Utilize a significant number of non-proprietary motors for goal demonstration, that have features and materials representative of operational motors Exit at a minimum of TRL 5 Publish results of effort at JANNAF meetings or other appropriate forums Actively participate in the programs IPT meetings Develop individual technology derived requirements from program requirements and methods to verify them (inspection, demonstration, test, analysis). The requirements and method are subject to approval by the integrated product team (IPT) Demonstrate reduced reliance on dissection of motors and depot operations to determine asset viability; and the ability to predict the lifetime of an individual solid rocket motor with greater fidelity over baseline Demonstrate use in environments for tactical and strategic missile systems to include, but not limited to, manufacturing, operational (for example: cyclic temperatures, vibrational loads, wind shear), motor handling, storage, and transport Demonstrate RP21 goal taking into account other factors to include, but not limited to, size constraints, data transfer, and other operational constraints Utilize open, well documented, and industry accepted standards Utilize technologies that are operable, sustainable, supportable, interoperable, modular, and reliable over the expected life time of the system for the operational users Develop a proposed concept of operation (CONOPs) for the technology as well as the method that will be used to integrate the technology into the operational system – not just the missile but the overall weapon system Report all results and test methods used throughout the demonstration Primarily apply to large scale monolithic and segmented SRMs such as may be used for strategic, space launch, and ballistic missile systems, and to tactical missile systems with minimal alterations All efforts that contain computer code/software shall:

Develop a sustainable code following modern software development practices such as version control; modular code; source code documentation; theory, developer, and user manuals; administrator guide; graphical user interfaces (as make requirement); regression suites; verification; and validation.

The code shall be capable of satisfactorily completing functional user testing to include installation and operation on current DoD standard desktop configuration client or DoD server core configuration connected AFRL’s SATURN enclave.

The code shall comply with AFI 33-210 certification and accreditation to including:

No CAT I or II finding of Security Technical Implementation Guides (STIG) Documentation of CAT III finding of STIGs that will be recommended for risk acceptance and the reasoning Draft 1.

Draft BAA-RQR-2014-0002

1. CALL 3 & 4 DESCRIPTION

A&S Technology Development Requirements:

Technology Development Objectives: This effort focuses on developing technologies including physics-based models and embedded sensor analysis technologies to meet the RP21 A&S goals. These technologies will appreciably increase our detection, prediction, and/or understanding of aging in SRMs and their safe operation.

All technology development efforts shall:

Illustrate reduction of reliance on dissection of motors and depot operations to determine asset viability, and logically lead to the ability to predict the lifetime of an individual solid rocket motor with greater fidelity Primarily apply to large scale monolithic and segmented SRMs such as may be used for strategic, space launch, and ballistic missile systems, and ideally to tactical missile systems with minimal alterations Designed for use in environments for tactical and strategic missile systems to include, but not limited to, manufacturing, operational (for example: cyclic temperatures, vibrational loads, wind shear), motor handling, storage, and transport Be designed taking into account other factors to include, but not limited to, size constraints, data transfer, and other operational constraints Surpass accuracy of previously funded efforts (for example: Service Life Prediction Technology [SLPT], Critical Defect Assessment [CDA], Sensors and Applications Modeling [SAM], Non-Destructive Evaluation Data Processing [NDE-DP], and various Advance Missile Propulsion Technology [AMPT] and Missile Component Advanced Technology [MCAT] Task Orders) in the area of SRM health modeling including, but not limited to, AFRL funded efforts (references are included in supplemental information package refer to BAA section III-5) Develop individual technology derived requirements from program requirements and methods to verify them (inspection, demonstration, test, analysis). The requirements and method are subject to approval by the integrated product team (IPT) Exit the technology development effort at a minimum of TRL 4 Use open, well documented, and industry accepted standards Confirm the proposed quantifiable improvement over the current state of the art along with how much they contribute to meeting the RP21 A&S goal and any impacts to other RP21 goals (Definitions are included in supplemental information package refer to BAA section III-5) Develop a proposed concept of operation (CONOPs) for the technology as well as the method that will be used to integrate the technology into the operational system – not just the missile but the overall weapon system Design technology that is operable, sustainable, supportable, interoperable, modular, and reliable over the expected life time of the system for the operational users Disseminate the results at JANNAF and/or other relevant forums Estimate the payoffs to the operational system Develop a plan to validate and verify technology for a future RP21 demonstration effort All efforts that contain computer code/software shall:

Develop a sustainable code following modern software development practices such as version control; modular code; source code documentation; theory, developer, and user manuals; administrator guide; graphical user interfaces (as make required); regression suites; verification; and validation.

The code shall be capable of satisfactorily completing functional user testing to include installation and operation on current DoD standard desktop configuration client or DoD server core configuration connected AFRL’s SATURN enclave.

The code shall comply with AFI 33-210 certification and accreditation to including:

No CAT I or II finding of Security Technical Implementation Guides (STIG) Documentation of CAT III finding of STIGs that will be recommended for risk acceptance and the reasoning Subtopic 1 Requirements: Physics-based modeling and their validation and verification All the modeling efforts shall:

Clearly define sources of error Perform a detailed uncertainty and sensitivity analysis of the model Develop a usable and highly automated code for distribution to the Government and their contractors Develop a code usable on a high power workstation – either Linux and/or Windows based Develop and document the necessary inputs for models throughout the life of the system including test methods for all modeling efforts Document all outputs from the codes Validate and verify codes (ref. 2 and 4), including development of experimental techniques as necessary Subtopic 3 Requirements: NDE Flaw Detection & material property determination The ability to determine material properties is crucial to the determination of aging in the propellant, liner, insulation, and case; a NDE technique capable of simultaneously measuring material properties and detecting motor configuration is highly sought after. A proposed NDE system focused on flaw detection should be able to achieve improved resolution compared to the current state-of-the-art (Hill AFB CT facility) for voids, separation, and inclusions. Additionally it should offer a sizeable logistic advantage over the current computed tomography method, determine material properties, and/or detect currently undetectable flaws such as kissing separations. Field-deployable, portable NDE systems (in silo) are preferred as these allow for more real-time fleet health awareness. The NDE system must be able to accurately track a detected flaw’s geometry throughout motor life, and be able to detect new flaws or cracks as they occur. Enhancing the capability to detect flaws and determine precise configuration in the forward and aft domes is highly desirable. It is important that this new technology is capable of being integrated with the ANDES/II software or follow-on software.

Subtopic 4 Requirements: Automated NDE Data and Evaluation System (ANDES) This technology development is either an enhancement to the ANDES/II software or a complete replacement that can evaluate a new solid rocket motor with minimal programming (ability to analyze one-of-a-kind motor compared to its design). It is highly desirable that the proposed solution integrate this technology with fracture mechanics and evolution models to achieve improvements in both diagnostic and prognostic capabilities in an automated fashion, and ideally with the existing Hill AFB CT system and developmental infrastructure. All efforts in this sub-area shall:

Develop automated method for analyzing NDE data to determine flaw size and location on any solid rocket motor with minimal reprogramming (<1 week) by comparing found flaws to the motor’s design model and/or technical order (if available) Develop automated method to predict flaw propagation and determine if and when the flaw will become critical Develop capability to export current 3D configuration to external analysis packages (e.g. ABAQUS, ANSYS Mechanical) Determine analytical uncertainty in each step of the development. During automated analysis the system should output the uncertainty magnitude Maintain all ANDES/II functionality and plan for a seamless transition between ANDES/II and follow-on/replacement Subtopic 5 Requirements: Sensors Successful, novel sensor technologies need to show a significant improvement over the current state-of-the-art. Each sensor will add increased inert weight to the motor, which is detrimental to RP21 mass fraction goals, thus the sensor will have to buy its way on board by providing critical motor health data. One of the critical challenges for this sensor development is the ability to identify and localize changes in a solid rocket motor, based upon a small, finite number of sensors. Chemical and embedded sensors need to address all of the following constraints in addition to their own unique constraints listed in call 3 sections I-1.7.2 and I-1.7.3, respectively. All proposed sensor development efforts shall:

II-1.1.1.1. Develop a sensor technology that enhances the ability to determine the current/future health state of the SRM with reduced uncertainty II-1.1.1.2. Demonstrate link between the sensor measurement and current and/or future state of the SRM II-1.1.1.3. Develop a temporally stable sensor without unpredictable drift and with exceptional reliability II-1.1.1.4. Demonstrate survivability of system in environments (as defined above), especially high energy x-ray CT, or mitigation methodologies II-1.1.1.5. Develop a sensor that can meet a missile system design life of at least 30 years II-1.1.1.6. Develop a sensor with minimum overall on-board mass and volume including any support hardware such as instrumentation lines to reduce impact on other RP 21 goals II-1.1.1.7. Develop a sensor whose power source has a minimal increase in consumption of logistic resources. If the sensor is to be battery powered it should last 25% longer than the sensors’ expected life, ideally the missile’s life II-1.1.1.8. Develop a sensor that, if it fails, fails in a safe, predictable, and detectable manner Subarea 1: Chemical Sensors In addition, all proposed chemical sensor development efforts shall:

II-1.1.1.9. Propose a credible link between detected chemical species and the condition of the motor, and a reasonable path to conclusively demonstrate this link II-1.1.1.10. Demonstrate conclusively the link between detected chemical species and the condition of the motor II-1.1.1.11. Demonstrate the ability to detect species without unpredictable drift or desensitization ideally for the expected life of the missile system, but minimally for seven years. Should the expected lifespan of the chemical sensor be less than the missile’s, the offeror needs a reasonable methodology for changing out the chemical sensor in the various operational environments Subarea 2: Embedded Sensors In addition, all proposed embedded sensor development efforts shall:

II-1.1.1.12. Develop embedded sensor and necessary automated analysis technology II-1.1.1.13. Demonstrate sensor, proposed power source, and operational means of accessing the data II-1.1.1.14. Demonstrate the exceptional reliability of the sensor systems as they cannot be replaced during the expected lifetime of the motor II-1.1.1.15. Show that the sensors are non-detrimental to the overall system capabilities, cost, and safety II-1.1.1.16. Show no significant increase in the probability of defect initiation and propagation or accelerated aging of the propellant, liner, or insulation II-1.1.1.17. Develop and test a method to retrieve the embedded sensor data from within the motor without violating any safety or security standards II-1.1.1.18. Confirm that the sensor technology minimally affects the current manufacturing process