FA8650-19-S-5002-Atch6.pdf

FA8650-19-S-5002

Attachment 6

Statement of Objectives (TO 0001)

Nondestructive Evaluation (NDE) Exploratory Development and Inspection Support for Air Force Systems

Task Order 0001 – Quick Reaction Nondestructive Evaluation, Characterization, and Support

29 October 2018

1. Objective

The objective of this Task Order is to provide the core technical effort for the Nondestructive Evaluation Exploratory Development program, for customers (USAF and non-USAF programs) supported by Materials Integrity Branch, System Support Division of the Materials and Manufacturing Directorate, Air Force Research Laboratory (AFRL/RXSA) in the areas of:

1.1. Rapid Response to Customer Critical NDE needs

1.2. Nondestructive Characterization of Emerging Materials and Structures

1.3. Inspection Equipment and Materials Performance Characterization

1.4. AFRL Failure Analysis Tasks

1.5. Teardown Projects

1.6. Structural Test Programs

2. Scope

2.1. This effort shall require the contractor to retain a core team of highly competent and certified NDE professionals to operate the NDE facility of the Materials Integrity Branch, System Support Division of the Materials and Manufacturing Directorate, Air Force Research Laboratory (AFRL) and to provide the Air Force with rapid reaction exploratory NDE development capability.

2.2. Provide for quick-reaction responses to address nondestructive inspection (NDI) issues, which affect existing weapons system operation and maintenance (O&M) capabilities, sustainment engineering concerns, or new procurement concerns as identified by Air Logistics Centers (ALCs), System Program Offices (SPOs) or any other customer supported by AFRL/RXSA, or weapon system safety as identified by the Air Force Safety Center

2.3. Provide for the nondestructive characterization of composite, metallic, ceramic and hybrid materials and components associated with structural, electronic, and propulsion systems and subsystems. These materials or components can be from systems in-service or under test and/or development.

2.4. Address the development of NDE techniques, procedures, reference standards, and inspection kits for application to high priority NDI requirements as defined by various customers including field, depot, Air Force Safety Center, the System Program Office (SPO) organizations, or any other customer supported by AFRL/RXSA. The program shall provide for transition of the resulting techniques, procedures, standards, as well as inspector training.

2.5. Keep abreast of changing system requirements and their impact on NDI materials and processes (M&P) and supportability issues by attending Air Force and DOD working group meetings related to NDI.

2.6. Keep abreast of current NDI state-of-the-art equipment and techniques as well as emerging NDI technologies for potential application to Air Force NDI requirements by attending technical conferences and meetings related to NDI technology development and application.

3. Background

3.1. Over the years, there has been a continued need for timely evaluation of manufacturing quality and structural integrity as it relates to nondestructive characterization of metallic and non-metallic materials. Other necessary issues include assessment of new, emerging, and commercially available NDE technologies, identification, and development of NDE techniques, procedures, and specialty hardware for Air Force inspection needs.

3.2. Unforeseen emergencies, urgent issues, and crises such as the “grounding” of aircraft due to Materials & Process (M&P) related issues or response to accident investigations, require rapid response; therefore, quick-reaction capability is required along with flexibility within the program to perform tasks as required

3.3. A team of on-site engineers and technicians, at the Materials and Manufacturing

Directorate, Area B, Bldg. 652, Wright-Patterson AFB, will be needed to support the core effort. Laboratory space, office facilities, and specialized equipment shall be provided as base support for this program. Existing Government owned specialized equipment shall be provided as Base Support to this effort.

4. Applicable Documents

4.1. NAS 410 Nondestructive Testing Personnel Qualification and Certification

4.2. SAE AMS 2644 – Materials, Penetrant Inspection

4.3. Wright-Patterson Air Force Base Hazardous Waste Management Plan

5. Technical Requirements

This effort will require the NDE team to operate the NDE facility of the Materials Integrity Branch of the Systems Support Division, Materials and Manufacturing Directorate of the Air Force Research Laboratory (AFRL/RXSA). The team must be certified to Level 3, as an aggregate, to the requirement of NAS 410, Nondestructive Testing Personnel Qualification and Certification, in the following five basic inspection methods: magnetic particle inspection, penetrant inspection, eddy-current inspection, radiography inspection, and ultrasonic inspection. Also as an aggregate, team members must have some experience with state of the art inspection technologies (e.g. digital radiography, x-ray computed tomography, phased array ultrasound, shearography, and pulsed thermography), and have demonstrated successful experience in applying NDI solutions to aircraft (structural and engine) inspection requirements. The team must also have a member who has demonstrated experience in the characterization of penetrant materials performance in accordance with SAE AMS 2644.

The team shall plan, accomplish, and manage technical efforts in the following areas:

5.1. Quick Reaction Response to Critical Air Force NDE Requirements. Quick reaction is defined as the ability to acquire physically specimens from AFRL/RXSA, test, and report preliminary findings within a 24-hour period. This support is required to allow the return to operational readiness of weapons systems that have been grounded because of M&P related issues, extend the useful life of existing systems, improve the system’s operational envelope, or take corrective actions for M&P deficiencies. Support must be initiated within 24 hours in response to requests from the Air Force program manager to urgent nondestructive inspection and characterization problems with affected systems.

The Government will provide specimens representing the material, structure, and nature of the problem upon which the contractor shall conduct the exploratory development necessary to apply NDE methods to access the structural integrity of the system or systems represented by these specimens. As dictated by the Air Force program manager, travel may be required to specified installations to further refine the methods developed in the laboratory for the system or systems under study and perform validation and verification demonstrations as required by the customer. While at the facility, the contractor shall employ the methods as required to detect and characterize similar problems on systems available. During this development activity, the contractor shall consult with customer and system manufacturer personnel as required. If required by the Air Force program manager, the contractor shall conduct Probability of Detection (POD) experiments to demonstrate the inspection solution will meet the customer’s detection capability requirements. The contractor shall document the development activities, findings and recommendations for solution to the problem submitted, and provide training to the customer as required.

5.2. NDE Development for Operations, Maintenance, and Sustainment Engineering.

Sustainment is defined as efforts used to ensure that the current generation fleet and/ or systems can efficiently perform their roles and functions. NDE plays a vital role in this effort. Efforts will include assessing, developing and transitioning NDE methodologies, techniques, and technologies for application to priority sustainment needs as identified by the System Program Offices, Air Logistics Centers, or any other customer supported by AFRL/RXSA. Compile the inspection requirements through consultation with the customer and the system manufacturer and coordinate the inspection requirements definition with the customer. Once the requirements are established, the contractor shall conduct the analysis and development required to address the inspection need and validate technology performance to meet customer requirements. The Government will provide representative material and/or structure. As dictated by the Air Force program manager, travel may be required to the requesting Air Logistics Center or pertinent field laboratory to further refine the methods developed in the laboratory. The contractor shall document the development activities, findings, and recommendations for solution to the problem submitted, and provide training to the customer as required.

5.3. Nondestructive Characterization of Materials and Structures. AFRL/RXSA will provide approximately 300 specimens or specimen sets per year for characterization. These specimens may be from in-service Air Force systems, AFRL developmental programs, or any other customer supported by AFRL/RXSA. These specimens or specimen sets will be accompanied with the details of their materials, design and expected properties of performance. Upon receipt of the specimens from the government, the contractor will select NDE methods for characterization. The methods to be considered shall include, but not be limited to, radiography, liquid penetrant, magnetic particle, magnetic rubber, eddy current, ultrasound, thermography, shearography, and Barkhausen noise analysis.

The specimens shall be characterized as received and returned to the government upon completion. The contractor shall accomplish routine characterization within 10 (ten) working days after receipt of the specimens. Characterization for high-priority, quick-reaction failure analysis shall be complete within three (3) working days of receipt of the specimen by the contractor. After completion of the characterization, the contractor shall document the results and recommendations as required by the customer.

5.4. Penetrant Materials Performance Characterization. Conduct penetrant performance characterization in accordance with AMS-2644 to address penetrant materials performance issues as they emerge. The specimens to be evaluated will be provided by AFRL/RXSA. In addition, the contractor will conduct special penetrant performance studies as requested by the Air Force program manager. These studies may include but are not limited to penetrant sensitivity studies, investigations of poor penetrant system performance, and assessments of factors effecting penetrant inspection effectivity. The contractor will conduct the required testing in accordance with AMS-2644, perform the analysis, and document the findings. All results will be delivered to the Government.

5.5. Laboratory Equipment. The contractor will operate and perform in-laboratory equipment maintenance to ensure the proper function of the laboratory Base Support equipment as required to conduct this R&D effort. If Base Support equipment is not sufficient to execute the effort, or the Base Support equipment requires repair, the contractor will notify the government. The contractor shall also purchase consumable materials as required to meet the rapid reaction requirements of this effort. In addition, the contractor shall be responsible for proper storage and disposal of all hazardous materials as directed by the Wright-Patterson Air Force Base Hazardous Waste Management Plan.

5.6. Procurement of Inspection Hardware. For any of the above tasks it may be necessary for the contractor to procure test equipment, not currently available in the laboratory or other locations, to ensure that the most complete testing is possible. This equipment can be instrumentation, fixtures, or standards. This equipment could serve as prototype and/ or preliminary test equipment for the other locations to perform acceptance testing for advanced applications. Equipment shall be described as prototype in that it has not been used by field or depot level inspectors yet, and may be true prototypes in that they have been developed specifically for an Air Force application. Discussion with the government will have deemed this equipment necessary and the most efficient solution to application. The contractor can procure this equipment in the manner they see most efficient.

5.6.1. Specialty Test Equipment (STE). This is for equipment currently not employed by ALC inspectors, but currently for retail sale. This equipment will be procured as first article testing equipment. These systems will have shown a capable of providing increased capability and/ or improved sensitivity for a given application. Depending on the application, this equipment may be transferred to the ALC’s for continuous use. In these instances, the government PM will handle the equipment transfer.

5.6.2. Prototype Equipment. This is for procurement of one off prototype systems, not currently for retail or for generic inspection problems. These items can be either be a combination of commercially available components packaged in a new format or constructed specifically for Air Force applications. Prototype equipment will be transferred to the requestor after finalization testing. All prototype equipment will be delivered to the government monitors who will distribute them the appropriate final location.

6. Management Functions

The contractor shall exercise administrative management functions during the course of this effort such as scheduling of activities and milestones; describing project status; outlining contractor activity and progress toward accomplishment of objectives, program planning, and describing in detail the overall results of the effort.

The contractor shall exercise financial management functions during the course of this effort such as planning, forecasting, and making recommendations on funding and funding changes.

7. Reporting Requirements

The following Contract Data Requirements (CDRL), DD Form 1423-1 applies:

7.1. A001 Scientific and Technical Reports, Final Report, DI-MISC-80711A/T

7.2. A002 Funds and Man-hour Expenditure Report, DI-FNCL-80331A/T

7.3. A003 Contract Funds Status Report (CFSR), DI-MGMT-81468/T

7.4. A004 Status Report, DI-MGMT-80368A/T

7.5. A005 Scientific and Technical Reports, DI-MISC-80711A/T

7.6. A006 Technical Report-Study/Services, Special or Project Report, DI-MISC-

80508B/T

7.7. A007 Test Plan, DI-NDTI-80566A/T

7.8. A008 Test Procedure, DI-NDTI-80603A/T

7.9. A009 Commercial Drawings and Associated Lists, DI-SESS-81003C/T

7.10. A010 Presentation Material, DI-ADMN-81373/TNon

8. Security Requirements

Operations Security (OPSEC) Requirements: All contractors shall follow appropriate OPSEC measures required for this particular contract. This is required in an effort to reduce program vulnerability from successful adversary collection of possible sensitive unclassified and/or proprietary information, and violations of export control requirements. The prime contractor will ensure that all subcontractors, if applicable, conform to these requirements as required by the prime contractor. Guidance can be provided by AFRL/RX Security as needed.

Program Protection Plan (PPP) – Any potential critical program information (CPI) generated, as part of this effort will be reviewed to determine the need for a PPP.