Atch 4 -MOC3HA-BASIC SOO.pdf

ATTACHMENT 4

MANUFACTURING OF CARBON-CARBON (C-C) COMPOSITES FOR HYPERSONIC APPLICATIONS (MOC3HA)

STATEMENT OF OBJECTIVES

22 November 2019

1. Background

Carbon-Carbon (C-C) composites are critical materials for many hypersonic applications. While the varying applications have different system requirements, they all leverage the unique high temperature performance capability of C-C composites. The C-C composite industrial base has seen mixed levels of activity as attention to military hypersonic applications has ebbed and flowed over the last several decades. A new initiative is needed to expand and deepen the C-C industrial base in order to successfully make hypersonic systems at the desired rates and costs.

The MOC3HA Initiative was established by the Defense Manufacturing Science and Technology (DMS&T) Office to address technology needs that transcend a single Service or agency. The chartered member organizations that are tasked with executing this Initiative are listed below.

• Air Force Research Laboratory, Materials and Manufacturing Directorate, Manufacturing Technologies Division (AFRL/RXMS)

• Naval Surface Warfare Center Carderock Division (NSWCCD)

• Naval Surface Warfare Center Dahlgren Division (NSWCDD)

• Combat Capabilities Development Command Aviation and Missile Center (CCDC AvMC)

• Combat Capabilities Development Command Army Research Laboratory (CCDC ARL)

• Missile Defense Agency (MDA)

• Defense Manufacturing Science and Technology (DMS&T) Office

A Working Group, comprised of representatives from each Service or Agency from the member organizations, will manage the day-to-day planning and execution of the MOC3HA Initiative. A Steering Committee, comprised of high-level leaders and subject matter experts from Department of Defense (DoD) and industry, will provide strategic technical and programmatic guidance to the Working Group and assist with technology transition. DMS&T will provide the funding as well as high-level guidance to the Government team. The members of the Working Group and Steering Committee, along with the Government program manager of this contract, are herein referred to as “the Government Team.” The primary technical interface between the contractor and the Government Team will be the Government program manager of this contract.

2. Scope

The objective of the MOC3HA Initiative is to create a stronger, broader supply base for C-C composites positioned to meet current and future DoD hypersonic systems’ requirements. This will require an Initiative Research Integrator (prime contractor) with strong program management and technical skills. The Government envisions a single Integrator (hereafter called “the contractor”) for all the efforts under this Initiative. The contractor’s efforts under the umbrella of this Initiative shall

Manufacturing Of C-C Composites For Hypersonic Applications (MOC3HA) Statement Of Objectives ensure proper financial, reporting and technical execution, as well as integration of the technical efforts. Technical efforts under the umbrella of this Initiative will be structured to develop C-C composite manufacturing technologies that enable the production at higher rates and quality, and at reduced cost and schedule.

3. Technical Management

Management of multiple subcontractors, as well as having multiple Government stakeholders, requires excellent program and financial management and reporting. It is critical that the contractor be able to satisfy the following technical management activities.

3.1. Classification and Limited Distribution Data

While the classification of each task order will be determined at the time the task order is issued, the contractor should be capable of processing classified material. This includes, but is not limited to, having access to secure means for transferring, processing, storing and discussing classified information both in person and over the phone. Refer to the DD254 of each task order for the highest level of security requirements.

This Initiative will utilize and generate proprietary, export controlled, or other limited distribution data. Any unclassified data generated as part of the MOC3HA Initiative, whether by member organizations, Government Team, or technical performers, will be marked “Distribution F. Further dissemination only as directed by the AFRL/RXM (date of determination) or higher authority.” Unclassified but distribution controlled data generated under this Initiative may be released to those working on the effort and who have a need to access the data for performance or contract management and monitoring, including the Government Team. Classified data distribution shall be controlled according to the relevant Security Classification Guide.

Security protocols for release at levels from Distribution B-E have been developed and are contained in the MOC3HA Security Policy. Any data that must be released at Distribution B-E must be reviewed by the Government program manager (who may require assistance from the Government Team) for appropriate releasability in accordance with the Security Policy.

At this point, no data is envisioned for public release. If any data would be authorized for public release by the Government, additional security protocols for public release of data shall be followed.

3.2. File Exchange

One of the primary goals of this Initiative is to develop and extend C-C composite manufacturing technologies and transition them to U.S. manufacturers. Therefore, it is anticipated that as much data as possible will be exchanged between member organizations and technical effort performers, as well as with the domestic C-C composites industrial base in general. It is critical that the contractor, its subcontractors, and Government Charter Organizations be able to exchange unclassified but limited distribution material in a secure and efficient manner. Data will include technical, programmatic, schedule, and financial data.

Different levels of access will be required so that proprietary and restricted access data can be accessed by the appropriate entities. Security of the data stored is of paramount importance due to the nature of this effort.

3.3. Task Order Establishment

This MOC3HA contract will be structured as an IDIQ with multiple delivery/task orders. The Government program manager for this Initiative, along with the MOC3HA Government Team, together will determine the technical requirements of each task order as the need arises. Task orders will be defined in accordance with the program objectives identified in Paragraph 4.0 of this SOO. The Air Force Contracting Officer will issue task orders, and no effort shall be conducted until such task orders have been awarded.

The contractor will determine the subcontracting needs on each task. If a subcontract is needed, the contractor will award to a qualified subcontractor. The contractor will be responsible for day-to-day task order/subcontract management, financial management, planning technical interchange and status meetings, and reporting to the Government.

3.4. Program and Financial Management

The contractor will provide sufficient program and financial information on a monthly basis for each task order as required to facilitate reporting to DMS&T and other stakeholders and funding organizations. Specifically, the contractor will conduct program and financial management functions such as: scheduling of activities and milestones for each task order;

outlining subcontractor activity and progress toward accomplishment of objectives and milestones; program and financial planning and forecasting; and describing in detail the overall conduct and results of the effort.

4. Technical Requirements

Under the MOC3HA Initiative, the contractor, in coordination with the Government Team, will plan and execute technical activities to achieve the objective. Individual task orders may require contractor personnel to attend meetings, symposia, and workshops with other researchers involved in similar technologies to add to the skills and knowledge base and achieve the objectives of the task order.

Specifically, technical programs may address, but are not limited to, the following targeted technology areas.

4.1. Variability Reduction

This technology development area will aim to reduce end-product variability by establishing a database as a means to display and analyze historical variations in production variables and end-product physical properties. This information, along with production-rate manufacturing trials, will be used to understand variability, devise methodologies to reduce it, implement those methodologies, and determine if and to what extent manufacturing variability has been reduced. Ultimately, the goal will be to reduce end-product variability, increase the number of “production-ready” vendors, and improve manufacturing modeling capability.

4.2. Automation of 2D and 3D Processing

The objective of this technology area will be to automate 2D and 3D preform fabrication in order to reduce cost and cycle time, increase quality and enable fabrication of larger sizes.

This may include focused efforts on fabrication with 2D prepreg or other preform production processes, novel or improved 3D billet production processes, as well as near net shape woven/braided/pinned, etc. structures. Additionally, the technology area will aim to automate component fabrication, to include, but not limited to, automated layup, prepregging, tape wrapping, sanding, machining, fiber placement, inspection, projected work instructions, etc. Ultimately, the goal will be to improve reliability and reproducibility of C-C composite components, reduce cost and schedule, and increase availability.

4.3. Accelerated Processing

Current processing methods employed for C-C composite high performance components take too long and cost too much. Various areas will be explored as a means to identify novel approaches which can be used to accelerate the densification processing schedule for 2D and 3D C-C composites. Topics may include, but are not limited to:

• Developing advanced densification processes to allow for increased volume capability as well as reduced densification timelines for a variety of possible manufacturing methods

• Developing force-cooled oven technology

• Developing larger/taller ovens and addressing the concomitant densification process requirements

• Evaluating new materials and tooling concepts to reduce cycle time

Ultimately, the goal will be to improve availability of C-C composite components, produce validated and tested components in less time, and to reduce overall cost and schedule.

4.4. 3D fiber preforms for improved properties

3D architectures, leveraging multi-axis reinforcements, have the potential to improve the properties of C-C composite material systems by optimizing the load carrying capacity.

This technology area will aim to understand, optimize, and validate fabrication process effects on composite properties with optimized multi-axis reinforcements for C-C composite components. Activities may include:

• A study of the 2D wrapping with stitching, Cartesian weave and 3D fabric architectures which are currently available and their advantages/disadvantages

• Developing models to quantify the material properties related to constituent materials, fiber architectures, and densified panels/components

• Developing 3D C-C composite systems including enhancement of weaving facilities for fabrication of advanced fiber architectures and thicker parts

• Densification of complex architectures

• Perform testing to characterize the material response, including quantification of the property distribution for both flat and shaped panels, and developing a material database for these improved material systems.

Ultimately, multi-axis composites with improved properties will advance C-C composite structures with low cost, high mass efficiency, high loading capacity, and high durability for a wide range of hypersonic structures.

4.5. Large and In-Process Inspection Methodologies

The objective of this technology area will be to develop, demonstrate and validate quantitative Non-Destructive Inspection (NDI)/Non-Destructive Testing (NDT), and in-process inspection methods for large and/or complex-shaped C-C composite structures in a production environment to ensure quality assurance metrics are met during processing steps as well as at the end of the manufacturing cycle. This will be accomplished by:

• Determining critical C-C inspection needs (in-process and post process)

• Leveraging polymer and ceramic matrix composite successes to identify mature NDI options

• Defining the insertion strategy (real-time in-process, processing gate, and final quality assurance inspection needs/options)

• Integrating and demonstrating the chosen techniques to determine effectiveness

• Identifying scale-up options for next-step opportunities.

Ultimately, the goal will be to meet the desired rates for large and complex C-C composite parts by improving the yield during the manufacturing process. Incorporating NDI techniques will reduce product/component variability, improve cycle time and cost, and increase confidence in product quality.

4.6. Large Parts and Preforms

This technology area will leverage customer needs and investments in capital equipment to scale-up engineering and analysis of 3D woven, 3D billet and 2D structural materials. The approach will involve creating prototypes of larger looms and tape wrap systems, as well as automated layup, weaving, wrapping, or other production systems. Ultimately, the goal will be to improve part throughput for larger size components and preforms, thus eliminating the need to join parts, or producing more items simultaneously. This will result in increased reliability and reduced weight, as well as cost and schedule improvements.

4.7. C-C Process Modeling & Integrated Computational Materials Engineering (ICME)

This technology area will aim to understand the state-of-the-art in modeling of C-C composite processing by performing a short technical analysis. Additionally, a survey will be performed with C-C composite users, producers and potential modelers in order to identify and prioritize the types of process modeling that would be most useful. The contractor will address the results of the research, as well as recommend development of high-payoff C-C composite processing/manufacturing models. Payoff will be defined as reducing development time and cost for new C-C composite components, increasing yield, and providing insight into sources of variability and low quality. If required, additional C-C composite process models will be developed. In addition, the contractor will recommend ways that the models should be transitioned to the C-C composites community for maximum impact as required for individual task orders that generate models. Ultimately, this information will help producers estimate final component properties and/or geometry, given a change in material or processing conditions, as well as allow them to choose a C-C composite processing method that is best suited for a particular component.

4.8. C-C Composites Testing

While some testing under MOC3HA may be done at the contractor’s or subcontractors’ facilities, much high-temperature or specialized testing will have to be done at other facilities, some of which are Government owned. The specific testing requirements will be defined in each task order SOO. The contractor will facilitate high fidelity testing while seeking to reduce costs and improve timeliness and quality of the testing. Tasks may include, but are not limited to:

• Survey test facilities to evaluate capabilities, costs, payment requirements, and availability

• Ascertain availability and costs of upcoming flight test opportunities, and make testing arrangements as necessary

• Arrange for high-temperature and specialized testing of samples generated under MOC3HA in blocks so as to generate data which can be compared easily while efficiently using Government funding. This is also anticipated to improve access to test facilities as compared to each individual entity arranging for its own testing.

4.9. Technical and Manufacturing Assessments

The contractor shall perform research and development using manufacturing technology analytical tools and research techniques including, but not limited to: Manufacturing Readiness Assessments (MRAs); Technology Readiness Assessments (TRAs); Key Performance Parameters (KPPs); process mapping tools such as Process Flow Charts and Value Stream Analyses (VSAs); process control tools such as Key Characteristics, Design of Experiments, and Statistical Process Control. The specific requirements for these types of assessments will be defined in each task order. It is anticipated that an MRA shall be required for each task order at the beginning and end of the task order, and, depending upon the period of performance, in the middle of each task order performance as well. The contractor shall measure and track these metrics throughout the course of the task order.

5. Funding

The anticipated funding profile is as follows:

FY20 FY21 FY22 FY23 Total

DMS&T $7M $7.755M $7.774M $7.773M $30.302M

Other $4M $4M $4M $4M $16M Total $11M $11.755M $11.774M $11.773M $46.302M

This profile aligns with the expectation that approximately 2-3 new task orders will be awarded each year, individually costing between $1M and $7M. The row labeled “Other” includes potential funding from DoD R&D organizations other than DMS&T; however, the amount and timing of these funds are currently an estimate.

6. Period of Performance

The completion date for the ordering period of this IDIQ, defined as the initiation of the final contract for technical effort let under the authority of the Initiative, is anticipated to be 5 years after initial award. The completion date for all technical effort is anticipated to be 2 years after the completion of the ordering period. Individual task orders are anticipated to have a period of performance between 1 to 4 years. However, the period of performance of any task order will not extend beyond 2 years after the ordering period. The exact period of performance will be specified in each individual task order.

7. Deliverables

7.1. Reports

For each task order, the Contractor shall deliver scientific, technical, and financial reports, to presentation materials. If the task involves the generation of software, the software product, as well as the software user manual, shall be delivered to the government. Finally, if created in the performance of the task, prototype hardware and/or test specimens shall be delivered as specified in the particular task order. Each task order will describe which specific CDRLs and hardware deliverables are applicable to that task order.

CDRLs under this contract include:

• A001, Scientific and Technical Reports, Final Report, draft due 30 days after the end of each task order

• A002, Funds and Man-Hour Expenditure Report, due monthly for each task order

• A003, Scientific and Technical Reports, Spend Plan, due monthly for each task order

• A004, Contract Funds Status Report, due quarterly for each task order

• A005, Status Report, due bi-monthly for each task order

• A006, Presentation Material, due as required

• A007, Software User Manual, due once for each task order which creates software

• A008, Computer Software Product, due once on each task order which creates software

• A009, Test Plan, due as required for task orders with significant testing

• A010, Test/Inspection reports, Test Reports, due as required for task orders with significant testing

• A011, Material and Processing Digital Data Package, due once at the end of each task order which generates scientific data

7.2. Hardware

Hardware deliverables will be on a task order basis, but may include: test specimens (either before and or after testing); demonstration articles (either before or after testing); and special purpose test equipment purchased as part of the performance of a task order.

7.3. Program Reviews and Status Meetings

The contractor will plan and execute Program Reviews on each task order every 6 months, to include one review annually where sub-contractors provide their first-hand technical accounts. It is anticipated that this review will include participation from Government stakeholders in addition to the MOC3HA Government Team. On occasion, tours and inspections of facilities utilized under the MOC3HA Initiative may be included as part of a Program Review.

In addition, it is anticipated that Status Meetings for each task order, to include technical, schedule, and financial information, will be required monthly. Most meetings will take place by telecom. It is anticipated that at least one Status Meeting per quarter will be face-to-face either at the Government’s facility, or at the discretion of the Government, at the contractor’s facility. The contractor will provide documents such as presentation charts as needed to convey critical program information for Program Reviews and Status Meetings.

7.4. Data Management

The data generated under each task order will be of interest and importance to the U. S.

domestic C-C composites and hypersonics community. Data generated under MOC3HA task orders will be managed and stored so that necessary data is available to all project participants and stakeholders when needed, within the limits of the distribution statements.

Retrieval shall be made as easy as possible while still adequately protecting it. Data distribution must be in accordance with its established distribution statement throughout its lifetime. Data for each task order may include, but is not limited to, analyzed technical data, program/financial/schedule data, software or models generated under the initiative, manuals, reports, technical papers, presentations, and metadata which describes or explains the data to include test conditions, manufacturing methods, etc.

7.5. Technology Transition

For each task order as required, the contractor will plan, coordinate, and conduct outreach activities to facilitate technology transition and implementation of the developed manufacturing technology at additional industrial facilities beyond the initial implementation site of any particular technical project. Outreach will be at the appropriate data distribution level. These activities include, but are not limited to, the following:

• Attending and showcasing the MOC3HA task order accomplishments at relevant conferences and trade shows with the appropriate attendance restrictions. Attendance and exhibition at trade shows, conferences, and the like must be approved in advance by the Government program manager. Typically this will be 2-3 events annually.

• Providing promotional materials and logistics for exhibits, demonstrations, conferences, workshops and/or displays.

• Providing presentations to be given by the Government Team to potential adopters of the developed manufacturing technologies and other stakeholders.

• Writing and distributing technical papers or presentations as a means of educating the industrial community on improved manufacturing technologies.

8. Security Requirements

8.1. Operations Security (OPSEC)

The contractor shall participate in all activities associated with the disciplines of the organization’s Industrial Security, Information Security, Personnel Security, Operations Security (OPSEC), Antiterrorism, and Program Protection programs. These are required in an effort to reduce program vulnerability from successful adversary collection, exploitation of critical information, and violations of export control requirements. The contractor will ensure that all subcontractors, if required, conform to these requirements as required by the prime contractor.

Guidance can be provided by AFRL/RX Security as needed.

8.2. 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 or to be included as part of an existing PPP.

8.3. Information Regarding Non-US Citizens Assigned to this Project

(a) Contractor employees requiring access to USAF bases, AFRL facilities, and/or access to U.S.

Government Information Technology (IT) networks in connection with the work on this contract must be U.S. citizens. For the purpose of base and network access, possession of a permanent resident card ("Green Card") does not equate to U.S. citizenship. This requirement does not apply to foreign nationals approved by the U.S. Department of Defense or U.S. State Department under international personnel exchange agreements with foreign governments.

Any waivers to this requirement must be granted in writing by the Contracting Officer prior to providing access. The above requirements are in addition to any other contract requirements related to obtaining a Common Access Card (CAC).

(b) For purposes of paragraph (a) above, if an IT network/system does not require AFRL to endorse a contractor's application to said network/system in order to gain access, the organization operating the IT network/system is responsible for controlling access to its system.

If an IT network/system requires an U.S. Government sponsor to endorse the application in order for access to the IT network/system; AFRL will only endorse the following types of applications; consistent with the requirements above:

(1) Contractor employees who are U.S. citizens performing work under this contract.

(2) Contractor employees who are non-U.S. citizens and who have been granted a waiver.