FA7000-15-R-0002_Att_6.a._Task_Order_0001_(T-38_ASIP).pdf

FA7000-15-R-0002

Section L, Attachment 6.a.

TASK ORDER 0001 WORK STATEMENT (WS)

ENGINEERING ANALYSIS ACTIVITIES IN AGING STRUCTURES:

USAF T-38 ASIP Support

1.0 BACKGROUND AND INTRODUCTION

1.1. Summary. The Center for Aircraft Structural Life Extension (CAStLE) at the United Stated Air Force Academy requires contractor support to perform multiple U.S. Air Force Aircraft Structural Integrity Program (ASIP)-related tasks for structural sustainment and structural sustainment research. The Task is described in paragraph 2. This Task Order (TO) supports the T-38 ASIP and analysis efforts of CAStLE and the Air Force.

1.2 Basic Contract and WS. Definitions of terms specific to this document or to the Aging Structures program can be found in the basic contract. Where specific taskings, terms, or conditions in this WS and contract/contract clauses conflict, this WS governs.

1.3 Scope and Period of Performance. The following sub-tasks are all required and are listed in order of their relative importance in terms of the T-38 ASIP and T-38 SPO’s management of the T- 38 fleet. In particular, this Task Order addresses the need for a more comprehensive and holistic review of the T-38 empennage and, more specifically, the horizontal stabilizer bearing support. For purposes of this TO, the T-38 empennage consists of the vertical and horizontal stabilizers, rudder, and the structure they directly attach to. To accomplish the goal of this TO, detail-specific research, testing, analysis, and non-destructive inspection (NDI) tools need to be considered. Each of the sub-tasks that support the overall effort are detailed in paragraph 2.

This effort is in direct support of the T-38 ASIP Manager’s ability to maintain engineering and technical capabilities for fleet sustainment out to programmed retirement. The expected period of performance is 12 months ARO, to be proposed by the contractor, and if necessary to be negotiated with the government prior to contract award.

1.3.1 Sub-Task 1 – Contractor Review of the T-38 Empennage. This sub-task provides for the basic research required to fully understand the workings of the horizontal stabilizer within the empennage (as a system). A visual description of the T-38 empennage is shown in Appendix A. The review will focus on the ability to manage the structure through sustainment, so knowledge of current inspection procedures of the empennage is vital. In the context of the entire Task, this research stage will provide direction towards any testing, analysis, and/or NDI tool development/procedures that can be developed, implemented or improved.

1.3.2 Sub-Task 2 – T-38 Specialized Structural Testing. This effort relies on the results of sub-task 1 and is dedicated to critical-part coupon and/or built-up structure testing of airframe details.

For the T-38 empennage, limited built-up coupon or material property testing is thought to be required in support of subsequent Fatigue-Critical Location (FCL) analyses. The contractor will propose a test scheme to the efforts of the TO. This sub-task is to be performed on a Firm Fixed Price (FFP) - Level of Effort (LOE) basis. Total hours of various labor categories defined by the offeror are not to exceed 732.

1.3.3 Sub-Task 3 – Static Strength, Durability, and Damage Tolerance Analyses. This sub-task will focus on evaluation of a damage scenario (based on field experience), the design of an appropriate repair (if practical), and a damage tolerance analysis (DTA) for a crack in the focus area. The use the AFGROW crack growth simulation tool is required. This sub-task is to be performed on an FFP-LOE basis. Total hours of various labor categories defined by the offeror are not to exceed 788.

1.3.4 Sub-Task 4 – Contractor Nondestructive Inspection (NDI) Support. This sub-task is directly related to the day-to-day airframe safety and long-term structural sustainment of the T-38 empennage. New and updated inspection procedures, developed as part of this effort, will be included in the T-38’s technical data. This sub-task is to be performed on an FFP-LOE basis. Total hours of various labor categories defined by the offeror are not to exceed 720.

2.0 DESCRIPTION OF SUB-TASKS. The contractor shall perform testing, analysis, and reporting efforts in accordance with the contract terms and conditions of this WS, the basic Work Statement and contract. The contractor shall furnish all labor, materials/other direct costs, transportation, storage, travel and support necessary to satisfactorily perform the efforts specifically identified in this WS.

2.1 Sub-Task 1 – Contractor Review of the T-38 Empennage

2.1.1 Sustainment. The contractor shall review the T-38 technical data to understand the current fleet management techniques used for sustainment of the empennage structure. In particular, the inspections in the area of the horizontal stabilizer outboard bearing support are of the most interest. However, it should be noted that a complete understanding of the entire empennage structure will be required, as the goal of this review is to develop recommendations for structural sustainment actions, in the context of the sub-tasks of paragraphs 2.2, 2.3 and 2.4, to keep the T-38 flying safely and economically until its programmed retirement.

2.1.2 Preliminary Reporting. Following the review required in paragraph 2.1.1, the contractor shall present the results of their research and preliminary evaluation/recommendations to the government as an interim technical report 30 working days after Task Order award. In addition to making structural sustainment recommendations, the contractor shall propose their approach to any testing required, including types and quantity of tests, to support subsequent analysis. In particular, a specific approach to how the testing (paragraph 2.2) will support the subsequent analysis and field-level inspections (paragraphs 2.3 and 2.4) will be required. This is a time-urgent requirement, so the proposed testing approach must show how test results will be obtained in the minimum possible time. The government will review the contractor’s technical approach and provide feedback to the contractor within 10 working days of receipt.

2.1.3 Initial Program Review. The contractor shall present the results of their research and preliminary evaluation, including structural sustainment and testing recommendations, to the government during a program review meeting. The meeting should occur within 10 working days from contractor receipt of the government’s comments. Following the program review, the goal of which is to develop a mutually agreed-to way forward, work on subsequent sub-tasks will begin at once. A final version of the interim technical report, capturing the input and discussions of the program review, will be due within 10 working days following the program review.

2.2 Sub-Task 2 – T-38 Specialized Structural Testing

2.2.1 Overview. This sub-task involves specialized testing of specific structural configurations, namely, the horizontal stabilizer outboard bearing support.

2.2.2 Testing Capabilities. As part of the proposal, the contractor shall clearly describe their structural testing and analysis capabilities that could be used in support of this sub-task and, if desired, how that capability will be fulfilled/augmented by USAFA test capabilities (see solicitation Attachment 10 for a description of USAFA laboratory capabilities and equipment).

2.2.3 Test Plan Development. Following the activity of Sub-Task 1 and receipt of Government approval, the contractor shall develop and deliver within 10 working days a test plan for government’s review and approval prior to proceeding with testing. The test plan shall include:

Hardware to be used for testing and its calibration state.

Test specimen detailed design.

The extent to which applicable ASTM test standards will be incorporated into testing and how compliance will be verified.

Instrumentation to be used on specimens.

Data collection (data type and frequency of collection).

A test matrix indicating test conditions for each test.

Government approval of the plan is required prior to proceeding with testing. Government comments will be provided within 10 working days of receipt of the draft plan.

2.3 Sub-Task 3 – Static Strength, Durability, and Damage Tolerance Analyses

2.3.1 General. Static strength, durability, and damage tolerance analyses are intended to be in support of the sustainment of the empennage, but not necessarily intended for inclusion within the formal reporting of the T-38 ASIP’s DADTA. The T-38 DADTA contains those fatigue critical locations (FCLs) that are used for the core management of the T-38 structure. At this time, it is not clear whether the horizontal stabilizer outboard bearing support (or associated structure) needs to be considered as an FCL (and thus included within the T-38 DADTA). Regardless, all types of analyses in support of those inspection intervals and repairs that are required for the fleet management of the empennage structure shall be considered.

2.3.2 Point Design. In accordance with the approved approach of Sub-Task 1, the contractor shall design a repair for the given damage scenario and perform a DTA for the damage within the repair for the horizontal stabilizer outboard bearing support. It should be noted that the exact details of the part may preclude it from being a candidate for damage tolerance analysis (e.g., the computed critical crack size is smaller than the NDI detectable size). Regardless, all analyses as described in paragraph 2.3.1. need to be taken to their logical conclusion in accordance with the Sub-Task 1 plan.

2.3.3 Finite Element Model/Analyses. If required as a result of the approved Sub-Task 1 plan, the contractor shall generate finite element models as necessary of the Appendix B detail (or possibly a different detail depending on the Sub-Task 1 recommendations) and perform finite element analyses to assist in the determination of the stress intensity factors, K, along the initial flaw crack front for a given load.

As part of the proposal, the contractor shall clearly describe their finite element analysis (FEA) capabilities including, personnel, software and hardware available to perform sound FEA.

2.3.4 DADTA Plan. In the event that the Sub-Task 1 structural detail of interest is designated as an FCL, the contractor shall prepare a DADTA Plan prior to proceeding with the damage tolerance analysis of the detail. The plan shall include:

The general approach for the DTA.

The expected fidelity of the DTA, citing sources of error(s) and their magnitude(s).

Government approval of the plan is required prior to proceeding with the DTA. Government comments will be provided within 10 working days of receipt of the draft plan.

2.4 Sub-Task 4 – T-38 Non-Destructive Inspection (NDI)

2.4.1 NDI Capabilities. The contractor shall describe in their proposal their NDI capabilities in terms of facilities, equipment and certified personnel available.

2.4.2 NDI Development Plan. The contractor shall develop a written plan for the NDI tool(s) and standard(s) to be developed for the structural detail decided upon in SubTask 1. The plan shall address the following elements:

Type of NDI method to be employed (eddy current, penetrant, etc.).

Guides or standards for calibration and/or use expected.

Expected level of NDI certification for technician employing the tool.

Expected detection capability (minimum detectable damage size).

Relationship between detection capability and ASC/EN Structures Bulletin ENSB08012.

Government approval of the plan is required prior to proceeding with the NDI development.

Government comments will be provided within 10 working days of receipt of the draft plan.

2.4.3 NDI Methods. Working in close concert with the T-38 ASIP and NDI Office, the contractor shall perform research to develop the necessary tools, methods and procedures for structural inspections in the empennage area. Following along with the results of analysis, the contractor shall focus their efforts on the detail identified in Sub-Task 1 for this sub-task.

2.4.4 NDI Tools. The contractor shall design the appropriate inspection tool and calibration standard(s) necessary to ensure an accurate and precise inspection procedure. Design drawings shall be included in the final report, as well as draft Technical Order pages for the proposed inspection, citing which Technical Order(s) would be affected.

2.4.5 NDI Tech Data Support. The contractor shall work with the T-38 ASIP and NDI offices to develop tech data pages that are ready for publication. As discussed in paragraph 2.4.4, the contractor shall provide the appropriate drawings for any tools or standards that could be incorporated into future Tech Order inspections. In addition, the associated procedures for any new inspections are also important for the contractor to support. The contractor can expect at least three iterations (for changes) during the tech data review process.

2.5 General Training and USAF/CAStLE Support. Cadet or other projects may be derived from the sub-tasks herein, and the contractor shall actively support CAStLE training and education of USAFA faculty, staff, and cadets on a limited basis as described in the basic contract.

3.0 REQUIRED DELIVERABLES

In addition to the basic contract CDRL items the contractor shall deliver the following reports and documentation.

3.1 Technical Reports. The following technical reports are due in addition to any deliverables required by the basic contract:

Sub-Task 1: T-38 Empennage Review – Preliminary Evaluation and Recommendations (DRAFT), due 30 working days after Task Order Award

Sub-Task 1: T-38 Empennage Review – Preliminary Evaluation and Recommendations (FINAL), due 10 working days after Sub-Task 1 program review

Sub-Task 2: T-38 Structures Test Plan (DRAFT), due 20 working days after SubTask 1 approval

Sub-Task 2: T-38 Structures Test Plan (FINAL), due 10 working days after receiving government comments on the draft

Sub-Task 3: T-38 DADTA Plan (DRAFT), due 10 working days after receiving notification that an empennage detail has been designated as an FCL

Sub-Task 3: T-38 DADTA Plan (FINAL), due 5 working days after receiving government comments on the draft

Sub-Task 4: T-38 NDI Development Plan (DRAFT), due 10 working days after receiving notification that an empennage detail has been selected for NDI development

Sub-Task 4: T-38 NDI Development Plan (FINAL), due 10 working days after receiving government comments on the draft

3.2 Presentation Materials. The following presentation materials are due in addition to any deliverables required by the basic contract:

Sub-Task 1: T-38 Empennage Review (DRAFT), due 3 working days prior to the program review

Sub-Task 1: T-38 Empennage Review (FINAL), due 3 working days following the program review

3.3 Final Reports. Final technical reports are required and shall be submitted to the government as per the definitions in the basic contract. DRAFT final reports are due 40 working days prior to the end of the period of performance, with the government having 20 working days for review.

Following the review, the contractor shall have 20 working days to make the necessary changes to the document for approval as a final report. The following are required and fulfill the basic contract final report requirement (A006):

Sub-Task 2: T-38 Specialized Structural Testing –Empennage o Appendix: Approved Sub-Task 2 Test Plan

Sub-Task 3: T-38 Damage Tolerance Analysis - Empennage o Appendix: Approved Sub-Task 3 DADTA Plan

Sub-Task 4: T-38 Nondestructive Inspection Tools and Methods – Empennage o Appendix: Approved Sub-Task 4 NDI Development Plan

3.4 Final Report Acceptance and Quality Assurance: The final reports of paragraph 3.3 must be approved by the T-38 ASIP Manager before they are deemed final and acceptable by the government.

4.0 GOVERNMENT FURNISHED PROPERTY

Outside of tech data, engineering models, and other engineering documentation, no other government furnished property, equipment, or information will be provided under this TO.

Because of distribution limitations, the contractor must request documents they determine necessary to prepare their proposal and execute the Task.

5.0 REQUIRED SUPPORT

The Contractor shall describe the need for the use of each category of support to meet the Task requirements. Proposed costs should be included in the accompanying cost/price proposal (solicitation Attachment 3a).

5.1 Travel. Travel will be required in support of this TO. The offeror will propose travel appropriate to the scope of the WS for any site visits, a kick-off meeting, technical interchange meetings, service trips, conferences, and program reviews.

5.2 Transportation. The Government does not anticipate transportation costs to be associated with this Task Order.

5.3 Storage. The Government does not anticipate storage costs to be associated with this Task Order.

5.4 Materials and Other Direct Costs. Materials will be required to fulfill the WS requirements.

Provide necessary quantities and types of material proposed, as well as the purpose of each item and its sub-task association.

Appendix A – Structural Detail for NDI Development (Sub-Tasks 1-4)

Figure A.1. shows an overview of the T-38 empennage; the subject area of this Task.

Figure A.1. Overview of the empennage area for NDI tool/method development.

Appendix B – Structural Detail for NDI Development (Sub-Tasks 1-4)

Figure B.1. shows a more detailed view of the empennage area, minus the horizontal stabilizers, and highlights the exact detail (i.e., bearing) for which an NDI tool/method needs to be developed.

Figure B.1. Detail of the bearing for NDI tool/method development.