Atch 5 -MOC3HA TO1 SOO.pdf

ATTACHMENT 5

Manufacturing of Carbon-Carbon Composites for Hypersonic Applications

(MOC3HA)

Task Order 1 Statement of Objectives

Effort: 1 Date: 20 Dec 2019

Title: Automation of Manufacturing Processes for 2D and 3D Carbon-Carbon (C-C) Composites

Value: $7.0M

Fiscal Year

FY20 FY21 Total

Amount $3.5 M $3.5M $7.0M

Period of Performance: 33 months after award date (30 months for technical effort plus 3 additional months for completing the final report).

Reference Basic SOO Paragraph(s): 3, 4.2, 7, 8

1. Background Carbon-carbon composites are a class of materials being considered for today’s hypersonic systems. In the past, large quantities of components made from these materials have not been produced, so development of automated processes has been slow. Hand manufacturing remains the state-of-the-art. A key objective of manufacturing research and technology is to help the Department of Defense reduce the costs and cycle times of acquisition of new systems. The focus of this task order is to automate manufacturing processes for carbon-carbon composites for hypersonic applications. This is to include all types of C-C: 2D; 3D; thermal protection systems (non-structural); and hot structural C-C.

2. Scope The research contemplated in this task order will include finding ways to automate manufacturing processes for C-C components; developing the hardware and software required to produce C-C parts; and validating that the parts produced are of adequate quality for application to military weapon systems. The contractor shall also document potential cost and cycle time savings anticipated from using the developed processes.

3. Objective The objective of this task order is to research, develop, design and prototype automated processes to manufacture C-C composite materials and components.

This research shall address technical, cost, schedule, and life-cycle implications of the manufacturing processes.

4. Description of Objectives

4.1. Novel Automation of Manufacturing Processes for 2D and 3D

Components In this subtask, the contractor shall research, develop, and prototype specific automated manufacturing technologies for C-C composites. Currently, many of the processes used to make C-C composites at industrial manufacturers involve hand processes such as lay-up, loading/moving/weighing of raw materials, prepregging, machining, etc. Use of automated processes is anticipated to reduce cycle time, increase quality, increase yield, reduce variability and reduce cost. All parts of the manufacturing process, and all types of processes may be addressed, but effort should be focused on those processes that can most benefit from automation. Automation of manufacturing of 2D (unidirectional or woven preforms), and 3D (for example woven, braided, 3D Cartesian preforms) shall be evaluated.

4.2. Production of Near Net Shape Components

In this subtask, the contractor shall research automated methodologies to produce near net shape components in situations when it is considered optimal to do so. Automation provides the opportunity to make components in a near net shape instead of in large billets or notional shapes that must later be machined to final shape. Machining is an additional process step that can increase cost, cycle time, and may damage the component, thus reducing yield.

In some cases, near net shape production is the desired way to make a given component.

4.3. Adaptation of Automated Processes from Other Industries

In this subtask, the contractor shall evaluate automated processes from other industries (such as ceramic matrix composites and polymer matrix composites) to determine if those technologies would be beneficial for adaptation to manufacturing of C-C composites. In many cases, processes (such as prepregging, layup, projected work instructions, and materials handling) have been automated and equipment may already exist that could be applied, with or without adaptation, to C-C composites. If such equipment or processes are determined to be beneficial, the contractor shall research, develop, and/or adapt those processes to manufacturing of C-C composites and prototype the manufacturing process.

4.4. Manufacturing of Larger Sized Components and/or Continuous Production

In this subtask, the contractor shall evaluate production of C-C composite components which must be joined or are made from a bulk billet to determine if manufacturing of larger sizes or continuous production would be advantageous.

In some cases, this might eliminate the need for joining or may improve efficiency, reducing cost. For selected components, the contractor shall research, develop and demonstrate manufacturing processes for larger sizes or continuous manufacturing.

4.5. Validation of Quality and Performance

As a part of any research, development, and demonstration under this task order, the contractor shall validate and quantify the quality of the materials produced in the automated process as compared to the state-of-the-art material or component, if it exists. Quality evaluations shall include, but are not limited to: material properties; component performance; and reduced variability of properties within a single component/material, between individual components, and between batches of material.

4.6. Demonstration of Reduced Cycle Time and Cost

The contractor shall demonstrate any reductions in cost or cycle time, or increases in yield, that can be anticipated though the use of the developed automated manufacturing technologies. The contractor shall perform a Manufacturing Readiness Assessment (MRA) at the beginning, middle, and end of the development of any individual manufacturing process. In addition, the contractor may use other assessment techniques as described in the basic contract (Basic SOO paragraph 4.9) for example, Technology Readiness Assessments and Value Stream Analyses. The contractor shall quantify anticipated reductions in cost and cycle time, and increases in yield or other cost-related factors, for each of the developed automated manufacturing technologies.

5. Deliverables:

5.1. CDRLs required: Final Report, Funds and Man-Hour Expenditure

Report, Spend Plan, Contract Funds Status Report (CFSR), Status Report, Presentation Material, Material and Processing Digital Data Package.

5.2. CLINs required: Research (0001), Hardware (0002)

Place of Review, Inspection, and Acceptance: Destination

Start Date: Award Date

6. Security Requirements

6.1. 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.

6.2. 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.

6.3. 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.