Attach-4-VIEW_SOO_Aug19_v2.docx.pdf

Statement of Objectives Variability Improvements in Engineered Windows (VIEW)

1. Introduction

The Air Force Research Laboratory, Materials & Manufacturing Directorate (AFRL/RX) is seeking manufacturing technology research and development focused on strengthening the defense manufacturing capabilities focused on those systems that can be utilized as transparent windows in environments beyond 1000°C for hypersonic platforms. These developments should occur through the discovery of new manufacturing capabilities or efficiency or quality improvements to existing manufacturing capabilities, and transitioning the developed capability to the factory floor. AFRL/RX is soliciting technical and cost proposals under this announcement to support the needs of its manufacturing and technology mission.

2. Manufacturing Research and Technology Development Approach

The Air Force Manufacturing and Industrial Technologies Division (AFRL/RXM) is requesting proposals to apply advanced manufacturing technologies to radio-frequency (RF) transmitting window systems. This interest is focused on improving manufacturing processes to reduce variability in RF performance in the final product. In addition to reducing performance variability through manufacturing processes the final product should seek to address two or more of the following goals: (1) reduce processing costs through the reduction of processing schedule or raw materials, (2) increase part rate production through the use of improved or alternate processing techniques to increase yield, (3) improve electrical and/or mechanical properties over current state of the art (SOA) through variability control, and (4) establish an assured and qualified supply chain from raw materials to finished product.

This technology domain aims to strengthen the industrial base capability to produce structural and functional materials for critical components for boost glide and air breathing high-speed vehicles. The proposed manufacturing process should be designed to consider the integration of the component into a relevant vehicle.

For this solicitation variability refers to dimensional, structural, and compositional tolerances that drive variance in performance properties. Items of interest are further described below. Each proposal should address all three areas, but proposals may choose to concentrate their effort in one or more areas.

2.1. RF Materials and Systems

The Air Force must to be able to operate effectively in anti-access, area-denial environments as well as be able to collect and potentially disseminate “real-time” data. This requires current and next generation high-speed platforms to have RF systems with improved capability, functionality, and performance. Due to the requirement to survive in high shear and high heat flux environments the components must perform as both a structural and functional component with tight requirements. Components must operate at temperatures above 1000°C for duration of the flight. The high level of integration required within these systems drives tight manufacturing tolerances that includes the need for low part-to-part variability. The Air Force objective is to increase the manufacturability, producibility, reliability, and performance for current and next generation high temperature RF systems. The focus is on reducing cycle time, part count, touch labor, and ultimately reducing the cost of RF components and materials. An area of emphasis is increased manufacturing readiness level and decreased transition and implementation risk. High temperature RF window materials include, but are not limited to, ceramic monolithic and composite materials. Temperature stable dielectric constants with low loss tangents are the most important RF properties. Proposals should show evidence of either directly measured or anticipated performance properties of the proposed materials made with initial manufacturing trials.

2.2. Manufacturing Technologies

Manufacturing technologies of interest are those that can improve current SOA processes or utilize advanced manufacturing methods in new ways.

Proposals should identify how improvements will be made. These improvements can include but are not limited to reducing processing steps, streamlining the process, reducing hand touch labor, reducing scrap, or improving the supply chain. The proposal should outline the current processing method and how the proposed work would address critical steps in the process to reduce variability.

Evidence of prior development work should be included to determine feasibility.

Performers will be expected to build at a minimum 10 plates of doubly curved window components or relevant shaped aperture plates with a transparent region of at least 5 x 9 inches and compare variability among the plates. Performance metrics to determine variability could include but are not limited to: (1) thickness tolerances of no more than +/- 0.002 inches and preferably +/- 0.001, (2) dielectric constant at room and elevated (1000°C+) temperatures of no more than +/- 0.15, and (3) minimization of the loss tangent. All plates should be analyzed for dimensional tolerance and all plates should be inspected for density and defect concentration utilizing current inspection techniques or those adapted from another industry. All techniques should have or should collect traceability to performance (mechanical, thermal, and electrical) properties.

All proposals should self-identify a starting and ending TRL and MRL of the proposed material system and manufacturing method. All proposals should identify how variability will be quantified and verified. Depending on the scope of the proposal, a MRA or similar evaluation may be warranted as part of the proposal.

2.3. System Design

All proposals should outline how the proposed manufacturing technology will fit into the production of the complete window system and address how any manufacturing changes will be confirmed to either maintain or improve integration to the platform. Proposals should outline which current or future Air Force hypersonic system(s) would benefit from the proposed improvements and define these benefits in terms of cost, availability, and/or performance. Evidence of ongoing or planned coordination or collaboration with hypersonic platform Primes and designers highlighting the relevance of the proposed processing and property improvements is encouraged.

3. Period of Performance

Each award will have an anticipated PoP to be between 18 to 36 months. This will include a technical PoP and an anticipated 3 month draft/final reporting PoP.

4. Deliverables

To be determined per award. See list of CDRLs attached to BAA.

5. Security Requirements

5.1. 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), and

Antiterrorism programs, following appropriate measures in each program as required for this particular contract. Security measures are required to reduce program vulnerability from successful adversary collection, exploitation of critical information, and violations of export control requirements. The prime contractor shall ensure all subcontractors, if applicable, conform to these requirements as required by the prime contractor.

5.2. Program Protection Plan (PPP) Requirements

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.