AFRL_RXNS_4D CT SOW_2024_04_23.pdf

Statement of Work for

2D/3D/Time Dependent Computed Tomography System

23 April 2024

AFRL/RXNSE

2179 12th Street

Wright-Patterson AFB, OH

45433-7718

I. Background: The requirements for a multi-purpose radiography suite are described below. The system SHALL be a fully functional, stand-alone system to be installed in an existing shielded vault within AFRL/RXNS laboratory spaces in Building 652 of the AFRL RX Complex.

Scope: The radiography suite will be used for still and real-time (video) high resolution 2D radiography and 3D computed tomography of a variety of components including electronic assemblies and components, avionics, structural materials and components made with various manufacturing methods including additive manufacturing. The suite shall also be used for 4D (time-dependent) reconstruction of dynamic systems to include materials and structures potentially under dynamic load and servo-mechanical or electrical systems dynamically energized.

II. Basic Requirements: The vendor provided system/ machine shall provide the following:

a. Still and real-time 2D imaging using a digital detector array

i. System shall produce X-ray images in the standard DICONDE format at a minimum

ii. System shall be able to produce .tif images or other high quality, high resolution, zero or very low compression image formats of all slices of the scans

b. Capability to combine image data from adjacent 2D and 3D data sets to build high resolution reconstructions for large components (i.e. data mosaic)

c. Automated computed tomography (3D and Time Dependent (4D) reconstructions) using digital detector array

i. Time Dependent reconstructions are a combination of 2 or more normal

CT reconstructions of a geometry when a series of loading or other movement conditions are applied and the geometry is re scanned. This can be seen to be similar to a tile mosaic of images (see above)

d. Ability to perform both stepped and continuous scans

e. Capability to perform imaging using both mini (450 kV) and micro (225 kV) focal spot tubes

f. Capability to perform sub-pixel image acquisition and reconstruction to improve spatial resolution.

g. Capability to perform helical scans

h. Scatter reduction for computed tomography through scatter control hardware and/ or software

i. Rotation stage with tilt set on 2 axes of translation (X and Z, Figure 3)

j. Computer workstation control of scanning and data acquisition

k. Separate workstation for post-processing/ reconstruction and analysis

l. Ability to add third party software to computers for additional analysis

m. Digital data storage capability for all imaging modes (all file formats and sufficient storage space), except for 2D radiographs using customer supplied imaging plates.

n. Capability for transferring digital data from and to the controlling computer for analysis, display and hard copy generation.

o. Ability to create and store user defined scan plans.

p. Active remote control of all axes.

q. Installation including transportation to installation location

r. Integration of system safety interlocks into existing vault interlocks.

s. Multi-Camera based monitoring system

t. Training

III. Facility Limitations for Delivery/Installation:

a. Max weight capacity of floor:

i. Corridors = 125psf

ii. Lab = 150psf

NOTE: These values come from the as built blueprints of the building and are described as live loads in the documents. More definitive weight requirements are provided in the section below. See note below in Section IV-a-ii

iii. Dead Load on Floor Slab: 3500 psi

Note: This load value should not come into play but is provided for knowledge

b. Clearance limits for hallways/doorways:

i. See Figure 1 for path from delivery location to laboratory location

ii. Max height = 84” (Doorway between loading dock and hallway)

iii. Max width = 58” (Doorway to lab)

NOTE: Two entry doors are available depending on final location of system components: 1) Sliding door to vault for manipulator and possibly generators and 2) double swinging door (1 full and 1 half width) for desk and other components

IV. Detailed System Requirements:

a. System Parameters:

i. Max System Dimensions (Assembled): 6’ (width) x 8’ (height) x 12’ (length).

This includes all detectors, x-ray tube, mounting frame, manipulating stage, pumps, generator(s), and any required space for access. (see Figure 2)

ii. Maximum weight, including manipulator, x-ray tubeheads and detectors: 6000 lbs.

NOTE: The weight and footprint for calculation of live loading is for manipulator system alone, including tubeheads and detectors. If generators must be located directly next to the manipulator system, they need to be included in this weight, but the footprint will need to be adjusted accordingly as well. If the generators can be moved sufficiently far away (2 feet minimum) then they do not need to be included in the weight/ footprint.

NOTE: To meet the weight capacity value in Section III-a-II divide the total weight of manipulator by the overall footprint of the system.

For a system weighting 4000 lbs and having a 5’ by 8’ footprint the area load would be 100 psf (4000 lb/40 sq ft). A system with a 40 sq ft footprint can have a maximum weight of 6000 lbs.

iii. System manipulator (motion axes) shall be shipped in as complete assembly as possible, but this is at the vendors discretion. Maximum weight of any single shipping crate/ container: 3500 lbs. Multiple shipping cases may be necessary to keep weight to below value above. Complete system shall be shipped in as few containers as possible.

iv. System control desk shall be capable of housing both data collection, and reconstruction workstations, all possible monitors provided, and any ancillary control hardware. A minimum footprint for all desk, control systems/ hardware, and all system components SHALL be provided with any quote.

All attempts should be made to minimize footprint of workstation desk and control hardware placed outside of vault space.

b. Stage Requirements

i. Stage Weight Capacity: 350 lbs minimum.

ii. Part Dimensional Capacity:

1. Height: 48 inches minimum

2. Diameter: 30 inches minimum

iii. Manipulation of inspection components:

Note: Described axis motions directions are based on Figure 3 at end of document

1. (Z-axis) Translation between detector and X-ray tube: Minimum of 47 inches measured from center of stage to X-ray tube focal spot

2. Automated rotation at user selected translation position for CT imaging

3. Scan Travel Dimensions: (See Figure 3 for Coordinate system axis)

a. Part Stage Rotation: 360 degrees continuous

i. Stage Resolution: 0.0025 degree maximum

b. Part Stage Tilt +/- 20 Degree

c. Part Stage X motion: 30” minimum

d. Part Stage Z motion: 45” minimum

e. Detector X Motion: 20” minimum

f. Detector Y Motion: 45” minimum

g. Detector Z Motion: 45” minimum

h. Tubehead Y motion: 45” minimum

i. Detector and Tubehead motion shall be capable of being decoupled, i.e the detector shall be able to move independently to the tubehead (2D and 3D mosaics)

c. X-ray Tube Requirements

i. Dual Tube Configuration

1. Microfocus Tube

a. Adjustable Energy Level: 25kV – 225 kV minimum

b. Adjustable Current Range: 0 mA – 3 mA minimum

c. Power Level: 300 W minimum

d. Focal spot size: <6 microns (achievable based on tube current)

2. Minifocus Tube

a. Adjustable Energy Level: 10kV – 450kV (maximum)

b. Adjustable current level: 0 mA – 4.0 mA minimum

c. Power Level: 1400 W minimum

d. Focal spot size: 0.4 mm and 1.0mm per EN 12534

e. Powered Shutter

3. System shall be capable of automatic tube switching

d. Digital Detector Array Requirements:

i. Flat Panel Detector

ii. Resolution: 16 bit minimum

iii. Minimum Active Area: 17” x 17”

iv. Max Pixel Pitch: 150 µm x 150 µm

v. Frame Rate: Adjustable with 15 FPS (minimum) using all available pixels, 25

FPS (minimum) with 2x2 pixel binning maximum

vi. Gadox Based Scintillator

vii. The position of the detector relative to the X-ray tube shall be adjustable from

12 to 44 inches (minimum) from the tubehead and shall be under computer control.

viii. Provisions allowing one person to easily remove and/or shield the detector to allow use of alternate detectors (i.e. computed radiography imaging plates)

e. Computer and Controls

i. The computers shall provide sufficient speed and performance to control of all system functions to meet all listed performance requirements. All computers shall be Windows based with the most up to date version of the operating system (Windows 10 Minimum)

1. The acquisition computer shall have a minimum of:

a. 8 core processor

b. 32 GB RAM

c. 1TB SSD operating drive

d. 3 TB storage drive.

e. DVD +/- RW Drive

f. 10/100/1000 Network Interface (LAN)

2. The reconstruction computer shall have a minimum of:

a. 10 core processor

b. 256 GB RAM

c. 1TB SSD operating drive

d. 24 TB storage drive with RAID5 capability

e. DVD +/- RW Drive

f. 10/100/1000 Network Interface (LAN)

g. The reconstruction computer should be the highest performing option available from the manufacturer or the one that provides the shortest reconstruction time and best data display with all possible data sets.

Ideally a minimum of 2 GPU’s but more would be preferred.

ii. Two color monitors (minimum of 1 per computer) shall be provided, each with a minimum screen size of 30-inch diagonal with 4K resolution or greater.

iii. Additional monitor for display of camera-based monitoring system.

iv. Each computer shall have a minimum of two USB-3.0 ports available for data transfer, etc. after all peripherals are attached. In addition, multiple

10/100/1000 (LAN) ports can be included in addition to the USB 3.0 to provide data transfer to external storage solutions.

v. The operator interface shall be at the workstation with commands entered at the keyboard and mouse. Additional manual control of all motorized axes shall be provided utilizing current push-button controls, joystick or pendant.

Axes positions shall be displayed on the monitor.

vi. All peripherals (mouse and keyboard) MUST be wired, no Bluetooth devices are allowed.

f. Software Requirements:

i. 2D Imaging Software

1. Non-proprietary image storage format, DICONDE Compliant, .tif format images or other high quality zero or low compression high resolution images

2. X-ray tube control, monitoring, and error logging.

3. Live image, integration and frame averaging, real-time contrast enhancement

4. Sharpening filter, smoothing filter, edge enhancement, Wallis, user definable filters

5. Histogram analysis, colorization and thresholding for density isolation

6. Image archival in at least TIF, BMP, and JPEG formats

7. Text annotation, fixed and real-time overlay (text, arrows, shapes, etc.)

8. Profile analysis function

9. Image spatial calibration and measurement in the X-Y plane (interactive)

10. Ability to acquire multiple 2D image results and combine into a single result

ii. 3D Reconstruction Software

1. Recording of projections

2. Both stepped and continuous CT scan creation

3. Detector correction (offset, gain, and missing pixels)

4. Image processing tools and projection filtering

5. Slicing (cropping) at multiple angles/planes(not just the x, y, z planes)

6. Histogram analysis, colorization and thresholding for density isolation

7. Filtering (Minimum): Average, sharpen, edge enhancement, Wallis

8. X-ray tube control and monitoring

9. High speed reconstruction of volumes or freely defined partial volumes

10. AVI file generation, video files must be high resolution, no or low compression (mp4 of similar)

11. Simultaneous acquisition and reconstruction of data

12. Capture of 2D images from any selected CT slice and output to at least

TIF, BMP, and JPEG. Output of full volumetric TIF stacks.

13. Dimensional measurement tools (linear and arc measurements)

14. Local reconstruction capability

15. Metric measurement tools per ASTM E2737 to include CNR, SNR, and

MTF (using E2002 unsharpness gauge)

16. Ability to perform helical scans to reduce parallax

17. Ability to acquire multiple CT results and combine/ stitch into a single result (mosaic and 4D/ Time and Motion, see III for more information)

18. Capability to achieve effective 75µm x 75µm detector resolution through detector fractional pixel shift or other means

19. Ring Reduction and Scatter Reduction algorithms

20. Creation and export of 3D surfaces as CAD model files

21. Ability to create standalone executable files of reconstruction results for manipulation on other workstations

22. Surface generation from CT scan Data, and ability to export this as CAD file format.

iii. Time Dependent (4D) and Motion CT Reconstruction

1. Provide all functionality required of 3D reconstruction

2. Provide capability to generate 3D reconstructions at successive time-frames and merge these reconstructions into dynamic reconstructions to enable analysis of state of change.

3. Again this is based on varied applied condition cases and repeat subsequent CT scans of a single part or geometry that are later combined to show how various components in the geometry are affects by the conditions applied

iv. Simulation Software

1. Windows based software that simulates the operation of the CT system which shall include the following items:

a. Technique Development

i. Software shall have operation and functions that can be adjusted in the simulation software to mirror those on actual system to take the parameters used and match them on the actual system to provide a scan as consistent as possible with the model outputs

b. Motion Programming

i. Software shall mimic the motion and scan options of the system such that the same options are possible when scanning the real part

c. Imaging Simulation

i. shall have the ability to export the same high quality zero compression still and video image formats as the actual system/ software

d. Ability to import both CAD model files and CT reconstructions to use for part creation

e. Ability to add multiple materials to a single geometry, if multiple items are present in geometry.

f. Ability to define custom materials based on a pre-populated repository and the ability to generate custom materials based on custom inputs

g. Ability to export CAD model files of optimized part orientation for use in creation of support structures

V. Vacuum Pump Requirements:

a. Roughing and turbo pumps shall be provided and integrated to support X-ray tube operation

b. All vacuum pumps shall be installed within the shielded vault.

VI. Generator Requirements

a. An X-ray tube generator(s) shall be provided to supply conditioned power to all tubes as required to meet the tube specifications

b. Sufficient cabling (10 meter min) shall be provided to interface the generator to the tube head

c. Generators may be installed within the shielded vault.

VII. Miscellaneous Requirements:

a. Microfocus Copper Filter Kit

b. Minifocus Copper Filter Kit

c. Tool Kits for system maintenance

d. 18” Turntable addition

e. Support frame on detector capable of holding Computed Radiography (CR)

Imaging Plates (IP) and DDA shielding with a maximum size of 14” x 17” in both hard and soft cassettes. Dimensional information on imaging plates and cassettes can be provided at request of vendor.

f. Micro positioner stage

i. Stage placed on rotation stage with ability to be removed when not needed

ii. 2 axis of travel with 10 µm minimum step size

iii. Control of motion from data collection workstation area. This can be from a separate control system or worked into the data collection work station.

iv. 100 mm min travel each

v. 20 lb capacity minimum

g. Filter Wheel

i. Minimum of 10 different filter options possible

ii. Motorized and computer controlled from software

iii. Pre-filled filter sections and blank sections for user defined options.

Provide details on filters for reference in quote.

VIII. Safety Requirements:

a. The system shall be integrated into the existing vault interlock system. The interlock includes internal and cut-off switch, warning lights and two door interlock switches. A wiring diagram can be provided upon request. Additionally this interlock system operates with our current general CR inspection area so continued and concurrent operation with this is needed as well.

b. The safety requirements and safety steps for the system must meet the requirements of T.O 33B-1-1: Technical Manual: Nondestructive Inspection

Methods, Basic Theory listed below.

“Interlock System. The visible and audible warning beacons/signals

SHALL be tied to an interlock system. The interlock system SHALL be placed on each door to interrupt power to the control box/tube head, stopping the irradiation process, when unauthorized access is attempted.

A time delay/interlock MAY be locally fabricated or purchased in order to meet this requirement.” “Warning Beacons. Rotating or flashing strobe-type visible warning beacons SHALL be used at all entrances to the enclosure.”

IX. Training:

The contractor SHALL provide on-site training for a minimum of five (5) days for a minimum of six (6) operators. Training SHALL cover advanced DR and 3D/4D CT methods, theory of operation, equipment operation, software operation, and system maintenance. The contractor shall provide necessary training documentation to include two (2) complete hardcopies and one (1) electronic copy of both the operation and system maintenance manuals. Training SHALL commence no later than two weeks following installation, or as agreed to by the contractor and the purchaser.

Contractor shall also provide for at minimum one (1) seat in a basic CT operation and technique development course offered by the contractor or a third party vendor agreed upon by the contractor and purchaser, and if available one (1) seat in an advanced CT technique development course. Any issues in training differences will be resolved by mutual agreement of the contractor and the Contracting Officer.

X. Installation

The installation SHALL include shipping, delivery, and installation of all hardware within the laboratory at AFRL/RXNSE. Calibration and checkout SHALL be performed, with the user as a witness, to demonstrate compliance to this specification.

a. No later than sixty (60) days prior to delivery, the contractor SHALL provide a facility plan that describes in detail the necessary utilities, the installation requirements necessary to set up this equipment, and the potential changes to the interlock systems to be operational as intended. This plan SHALL be submitted to AFRL/RXNSE to allow for customer site preparation prior to installation. If necessary onsite visit(s) can be arranged to allow for the vendor to fully understand the access routes and the installation challenges.

b. The site will be ready for installation within sixty (60) days after receipt of the facility plan.

c. Installation and testing SHALL be accomplished at a time agreeable to both the contractor and customer but no later than fourteen (14) days after delivery of the equipment. If installation and testing will not be possible within 14 days of delivery, AFRL/RXNSE will notify the contractor and a mutual agreement will be reached between the parties as to action to be taken.

d. Acceptance/Testing: Final inspection and acceptance will be made by

AFRL/RXNSE personnel after the equipment is installed, is operational and has been verified, through test and demonstration, that it meets the requirements of this specification.

XI. Security Requirements

a. Operations Security (OPSEC): The contractor shall participate in all activities associated with the disciplines of the organizations Industrial Security, Information Security, Personnel Security, Operations Security (OPSEC), and Antiterrorism program, following appropriate measures in each program as required for this particular contract. Security measures are required to reduce program vulnerability from successful adversary collection, exploitation of critical information, and violations of export control requirements. The prime contractor shall ensure all subcontractors, if applicable, conform to these requirements as required by the prime contractor.

b. Program Protection Plan (PPP) Requirements: Any potential critical program information (CPI) generated as part of this effort will be reviewed to determine the need for a PPP or to be included as part of an existing PPP.

XII. Options:

1) Integration of a linear detector and associated data collection and reconstruction software. This detector shall be permanently mounted adjacent to the flat-panel detector required in the base system and have the following specifications

a. Pixel Pitch: 500 micron maximum

b. 24 inch length minimum

c. 16 bit resolution

d. Automatic detector switching

e. Collimator

Figure 1. Delivery Path with Dimensions

Figure 2. Location and footprint of multi-purpose radiography system

Footprint for multi-purpose radiography system 6 ft

12 ft

5 ft

5 ft 4 in

1 ft

5 ft

5 ft

2 interlocked doors

Serpentine cable passage (5”x7” min opening*)

*shared with two other x-ray tubes and electrical runs

38 in

Figure 3. Coordinate system for axis movement.