DCPD System Product Description.pdf

PURCHASE

DESCRIPTION

for

DIRECT CURRENT POTENTIAL DIFFERENCE

CRACK MEASUREMENT SYSTEM (DCPDS)

for the

809th SCIENCE & ENGINEERING LABORATORY

(809 MXSS/MXDTAC)

Hill AFB, UT

19 JAN 2023

1. SCOPE:

1.1. This purchase description (PD) covers detailed specifications and performance requirements for a Direct Current Potential Difference Crack Measurement System for 809

MXSS/MXDTAC at Hill AFB, Utah. The Direct Current Potential Difference Crack

Measurement System will be referred to as DCPDS throughout this PD. To acquire a

DCPDS to enable precise measurements of crack length during testing by changes in electrical properties.

2. OVERVIEW:

2.1. Acquisition of a DCPDS will provide new fatigue testing capabilities for detecting and measuring crack growth during fatigue testing. Fatigue crack growth rate is a critical parameter for qualifying additively manufacturing processes and components. A key benefit of the DCPDS is detection and measurement cracks in areas of a part that cannot be easily accessed for visual measurements (such as internal cracks). The DCPDS will be used to support additively manufactured metal components for use on weapons systems such as A-

10, C-130, C-17, F-16, F-35, KC-135, T-38, Ground and Shop Support Equipment and

Structures, Vehicles, Missile components, etc.

3. SYSTEM DESIGN:

3.1. ENGLISH: All documents and software submitted by contractor to USAF contracting office must be in American English. All documents and software provided with DCPDS must be in American English.

3.2. The DCPDS shall be new and one of the manufacturer's current production models, which, on the date of the solicitation, has been designed, engineered, sold or is being offered for sale through advertisements or manufacturer's published catalogs or brochures. The DCPDS shall be an off the shelf design meant for a production level testing environment. Products such as a prototype unit, pre-production model, a repaired unit or an experimental unit do not qualify. The system shall include all components, parts, and features necessary to meet the requirements specified herein and be complete and ready for use.

3.3. The overall DCPDS shall meet the following minimum requirements:

3.3.1. Shall be capable of providing crack length information using the DCPD method.

3.3.2. Shall be designed to interface with existing MTS FlexTest 40 digital controllers. Adapters are allowed.

3.3.3. Shall be capable of controlling a cyclic fatigue test based on crack length measurements.

3.3.4. Shall include in-depth user training on the setup and operation of the system.

3.4. The hardware provided with the DCPDS shall meet the following minimum requirements:

3.4.1. Shall include a power supply, amplifier, digital signal processor (DSP).

3.4.2. Shall be capable of interfacing with existing MTS FlexTest 40 digital controllers.

3.4.3. Power supply must be capable of supplying 20 amps (A) direct current (DC) at 5 volts (V) DC.

3.4.4. Power supply noise must be less than 5 mA peak-to-peak at 5A.

3.4.5. Power supply must be capable of reversing current at a manual or programmatic command.

3.4.6. Amplifier gain must be adjustable with a range of 500 to 40,000.

3.4.7. Amplifier must have a display which shows current output voltage.

3.4.8. DSP must have 8 analog inputs, 2 analog outputs, and 8 digital I/Os.

3.4.9. DSP must have 16-bit analog input and output resolution

3.4.10. DSP must have 1GB of internal memory.

3.4.11. DSP must be capable of 64-bit floating point calculations

3.5. The software provided with the DCPDS shall meet the following minimum requirements:

3.5.1. Shall be capable of controlling fatigue crack growth rate tests with the following capabilities:

3.5.1.1. Constant-amplitude, variable-amplitude, and custom waveforms.

3.5.1.2. DCPD and compliance methods of monitoring crack length.

3.5.1.3. Integrated support for standard geometries.

3.5.1.4. Control test using either stress intensity or load signals.

3.5.1.5. Adaptive tuning for ensuring variable-amplitude endpoints are achieved.

3.5.1.6. Save adaptive tuning for subsequent tests.

3.5.1.7. Tools for analyzing accuracy of variable-amplitude loading.

3.5.1.8. Crack closure measurements.

3.5.1.9. Adjusted compliance ratio capability.

3.5.1.10. Crack length postprocessing.

3.5.1.11. Visual displays of critical test parameters and signals.

3.5.2. Shall be capable of controlling fracture toughness tests with the following capabilities:

3.5.2.1. Linear-elastic or nonlinear testing.

3.5.2.2. DCPD and compliance methods of monitoring crack length.

3.5.2.3. Adjustable data collection rates.

3.5.2.4. Visual display of critical test parameters and signals.

3.5.2.5. Saves test data for future use.

3.5.3.

4. OTHER DELIVERABLES:

4.1. WARRANTY: The successful bidder (contractor) shall provide a minimum one-year warranty which warrants all products provided under this contract, under normal use, to be free from defects in materials and workmanship and that the DCPDS will perform its design function for a period of no less than one (1) year. Warranty period to start from date of final acceptance. Any defects in materials or workmanship or failure of any product or component to perform its designed function during the warranty period shall be repaired by the contactor at no additional cost to the government. The contractor shall provide, free of charge, software updates and/or system upgrades that are released during the warranty period. Warranty shall include the cost(s) of: parts, shipping, labor and any travel related expenses. Warranty repairs which present a safety hazard are to be addressed within 7 business days of notice of failure. Non-safety related warranty repairs are to be addressed within 15 business days of failure notice.

5. AFTER CONTRACT AWARD:

5.1. The contractor shall deliver the DCPDS within 100 days. The contractor shall be responsible for the packaging and shipment of DCPDS to its final destination IAW standard commercial practice. Contractor shall make all arrangements necessary and cover all costs to deliver DCPDS and all related equipment, supplies, materials, fabrications, etc. to the job site at Hill Air Force Base, Utah. Contractor shall coordinate delivery and off-loading with the government representative (GR) from 809 MXSS/MXDTAC. The contractor shall supply and deliver operations/maintenance manuals upon delivery of the DCPDS or sooner.

Failure to meet all requirements outlined in this PD shall be grounds for rejection.

5.2. Training:

5.2.1. At no additional cost, the vendor shall provide DCPDS training. A qualified, factory trained on DCPDS, specialist(s) must provide training for at least two 8-hour days, at either Hill AFB, Utah or the manufacturer’s facility.

Training, at a minimum, shall include:

5.2.1.1. DCPDS System Introduction

5.2.1.2. Setup procedures

5.2.1.3. Integration with existing systems

5.2.1.4. Running fatigue crack growth rate tests

5.2.1.5. Running fracture toughness tests

5.2.1.6. Running tests with variable amplitudes

5.2.1.7. Data postprocessing

5.2.1.8. Shut Down procedures

5.2.1.9. System Care & Detailed Maintenance

5.2.2. All labor, food, travel and accommodation expenses for the applications specialist(s) to make on-site visit (if applicable) shall be included.

**Attention**

All line items for this purchase order shall be shipped to the following address:

7278 4th Street

Hill AFB, UT 84056

Attn: Evan Ross