PWT_16T_Comp_C1_Blades_RFI_v_04.pdf

Approved for public release; distribution is unlimited. AEDC2016-274

REQUEST FOR INFORMATION (RFI)

FA9101-17-R-1000, Wind Tunnel Compressor Rotor Blades

05 October 2016

THIS ANNOUNCEMENT IS NOT A NOTICE OF SOLICITATION ISSUANCE. THIS IS A REQUEST FOR INFORMATION (RFI) FOR PLANNING PURPOSES ONLY. This RFI is ISSUED for the purpose of developing a viable solicitation that will best communicate the Government’s requirements to industry. Response to this RFI is strictly voluntary and will not affect any firm’s ability to submit an offer if, or when, a solicitation is released. The requested information is for planning purposes only and does NOT constitute a commitment, implied or otherwise, that a procurement action will be issued. No entitlement to payment by the Government of direct or indirect costs or charges will arise as a result of the submission of information in response to this RFI. The Government shall not be liable for or suffer any consequential damages for any improperly identified proprietary information. Proprietary information will be safeguarded in accordance with the applicable Government regulations. Formal notices will be on posted on the Federal Business Opportunities (FBO) website, http://www.fbo.gov/ .

GENERAL INFORMATION: The Air Force Arnold Engineering Development Complex (AEDC) is in the process of determining the acquisition strategy for the design and manufacture of rotor blades for the Transonic Wind Tunnel 16T Main Compressor.

System Description: Transonic Wind Tunnel 16T and Compressor C1

Tunnel 16T is the largest transonic tunnel in the U.S. and provides critical aerodynamic test and evaluation (T&E) data necessary for flight vehicle development. Tunnel 16T has a large test section (16-ft. x 16-ft. x 40-ft) and wide Mach Number range (0.05 to 1.6) which make it an optimum source for the high-quality transonic data needed by the DoD. A single main compressor, designated Compressor C1, provides the primary air flow in Tunnel 16T.

Compressor C1 has an inlet diameter of 30.2-ft. and has three rotor stages containing a total of 97 compressor blades (see Figure 1). The Compressor is driven by four electrical motors. The compressor operates in two speed-modes: a variable speed mode is used to produce test-section velocities between Mach numbers 0.05 and 0.6 (using rpms less than 600 rpm); a constant 600 rpm speed mode is used to produce velocities from Mach 0.6 to 1.6. The compressor also has variable-pitch stators located at the compressor inlet, between each rotor (stage), and at the exit. The rotor blade rows (stages) differ by the number of blades and the blade-to-rotor attachment angle. The rotor blades differ only by the geometry of the blade cuff (a different cuff is used for each rotor stage). The rotor blades are cambered, twisted, and tapered. The rotor blades (see Figure 2) are a composite fiberglass reinforced plastic (FRP) construction with metal reinforced blade-roots and pin-bushings at the blade-to-adaptor interface. The rotor blades are ~7.0-ft. tall. The rotor blades as well as any other rotating component of the compressor are critical components, since failure would result in considerable damage to the machine and delay testing operations. AEDC has complete drawings of the existing FRP rotor blades as well as operational and design data.

Figure 1.0 Tunnel 16T Compressor C1 General Arrangement http://www.fedbizopps.gov/

Figure 2.0 Tunnel 16T Compressor C1 Rotor Blade (Typical)

Program Description

The AEDC Compressor C1 Blade Replacement Project has been initiated and is funded by the United States Air Force Test Investment Planning and Programming (TIPP) process. This RFI covers the analysis, design, tooling, testing, and manufacture of composite rotor blades for Compressor C1.

AEDC currently envisions this acquisition will be structured in two phases:

1. Design and Prototype Phase: This phase includes blade analysis and design, production tooling design and fabrication, prototype blade manufacture, blade inspection and repair demonstrations, prototype blade development testing (includes materials testing), and prototype blade acceptance testing and reporting.

The final configuration prototype blades will be of “production” configuration and use production-like manufacturing processes.

2. Manufacturing Phase: This phase includes the manufacture of two sets of production configuration blades preceded by a small quantity of low-rate initial-production (LRIP) blades. LRIP blades will undergo a higher level of inspection and testing prior to full-rate manufacturing. The manufacturing phase will not start until Phase 1 is completed. Production of the two blade sets will be staged: the production of the second set of blades will be delayed until after the first set production blades has been installed into Compressor C1 and passes AEDC operational tests. (Note: AEDC will be responsible for blade installation and operational testing, these activities are not within scope of this program).

The primary objectives of this program are:

1. Provide 2 complete sets of Compressor C1 “Production” rotor blades and 10 prototype blades. A single set is 97 blades.

2. Manufacturing of the first full-set of “Production” blades will occur only after the prototype and LRIP blades have been fully evaluated and accepted.

a. A set of 10 prototype blades will be acquired for testing and evaluation purposes.

b. At least three LRIP blades will be acquired and tested prior to commencing full-rate production.

c. Prototype blade tests will include materials characterization, static loading, and damage characterization.

d. At least three prototype blades will be installed on one C1 rotor for operational testing (cost of this operational test is not within scope of this program; AEDC will fund this evaluation test).

3. Delivery of all rotor blades is to be by the end of FY 2022.

Airfoil Cross Section

Blade Root Attachment Bushing and Cuff

4. Rotor blades will be strengthened (over current design) to allow operation of Compressor C1 at higher power. The target Compressor input horsepower increase is 30 percent (above current operational limit)

5. The target rotor blade operational life is 20 years and over 30,000 compressor loading cycles.

6. The current target blade operational temperature is 300 deg F. This target temperature may change (i.e., increase).

7. Rotor blades will be constructed from composite materials to ensure target blade-weight, strength, and stiffness criterial are met: the goal is to save weight if possible but, at a minimum, to prevent increasing the centripetal loading on the Compressor C1 rotor disc.

8. Rotor blades must not negatively impact the aerodynamic performance (e.g., compressor stall performance, pressure ratio, and efficiency) and operating characteristics (e.g., loads, vibrations) of Compressor C1.

a. To ensure aerodynamic performance is retained, AEDC will require that the outer mold line (OML) and shape of the existing FRP blades be retained.

b. Other rotor blade characteristics, such as weight, center of gravity (c.g.), stiffness, and resonant frequencies, must be carefully chosen to ensure operational characteristics are retained over the full Compressor C1 operational envelope.

9. Rotor blades frequently receive foreign object impacts and foreign object damage: the ability to easily inspect (as installed in the compressor and with blade removed from the compressor) and repair (with blade removed) are critical program goals.

10. Resources, logistics, tools, and processes required to inspect and / or repair the new rotor blades must be equivalent to that of current FRP blades. AEDC has considerable experience with inspection and repair of our existing blades: any new processes, material, or equipment that impacts our ability to quickly perform in-tunnel inspection of “installed” blades is not desired as this directly impacts test throughput.

Additionally, increases in the cost, complexity (e.g., tools / instrumentation), or time required to perform more detailed non-destructive inspections (NDI) of removed blades is also not desired. Finally, repair processes should be similar to typical scarf repairs which AEDC uses on our current fiberglass reinforced plastic blades.

11. Manufacturing tooling is to become the property of the Government to facilitate future blade manufacturing.

12. Data rights for the blades, including manufacturing process procedures and all drawings, are to become the property of the Government to facilitate future blade manufacturing.

PURPOSE: AEDC intends to use the information gathered from this effort to begin to assess capabilities and interests in all aspects of the work to be performed. In order for AEDC to begin its assessment, please respond to as many of the following questions as you can or are applicable to your company.

1. Complete the table on the following page for each Attachment 1, Work Breakdown Structure (WBS) Element, in accordance with the following instructions:

WBS Phases are:

1. Design and Prototype Phase

1.1. Composite rotor blade composite structure analysis and design

1.2. Tooling design for composite rotor blade manufacturing

1.3. Tooling fabrication for composite rotor blade manufacturing

1.4. Prototype blade composite rotor blade fabrication

1.5. Composite materials and rotor blade testing (includes damage testing)

2. Manufacturing Phase

2.1. Full rate composite blade production

2.2. Composite blade inspection and acceptance testing

a. Capable – Does your company have the capability to perform the blade design and analysis (including tooling), testing, tooling production, and blade manufacture for AEDC? If you have only a partial capability, indicate the extent of the capability (i.e., wind power, wind tunnels, design only, or fabrication only). List any capabilities which you would team with another contractor.

b. Interested – Is your company interested in potentially competing for the entire scope of this effort or a portion thereof?

c. Total Experience – How many years has your company performed this type of work?

d. Government experience – How many years has your company performed this type of work on a

Government contract?

e. Recommended Contract Type – What contract type would you recommend for each phase work (e.g., Cost Plus Incentive Fee (CPIF), Firm Fixed Price (FFP), etc.)? Please explain your reasoning.

f. Minimum Period of Performance – To be worthwhile to your company, what is the minimum period of performance you would recommend each of the Program Phases (1 and 2)?

WBS Element

Capable In total or in part?

Interested In total or in part?

Total Experience

Gov’t Experience (contracts)

Recommended Contract Type

Minimum Period of

Performance

1. Design and

Prototype

1.1 Composite

compressor rotor blade structural analysis and design

1.2 Tooling design for

composite rotor blade manufacturing

1.3 Tooling fabrication

for composite rotor blade manufacturing

1.4 Prototype

composite rotor blade fabrication

1.5 Composite

materials and prototype blade testing (includes damage)

2. Manufacturing

2.1 Full-rate Composite

Blade Manufacturing (100+ blades)

2.2 Composite Blade

Inspection and Acceptance Testing

2. What outer surface finish can be obtained on composite blades of this type?

3. Has your company provided composite structures for man-rated aerospace vehicles?

4. Please provide any additional thoughts or recommendations you have regarding possible strategy options and contract types for the Compressor C1 Rotor Blade Program, including single awards, multiple awards, and small business set asides.

5. Please describe any involvement your company may have had in contracts similar in nature to the areas in which you have expressed an interest.

6. If major portions of the AEDC contract (e.g., Design and Prototype, Tooling, and / or Production) were awarded to different contractors, how would you recommend the USAF incentivize cooperation/coordination to ensure smooth execution of each program element or phase?

7. Would you participate in the acquisition with other firms as teaming members or joint ventures? What other teaming opportunities do you see for this acquisition?

8. What quality assurance processes does your company employ (e.g., ISO 9000, AS 9100, or other)?

9. Please identify the North American Industry Classification System (NAICS) code you think is appropriate for the areas in which you have expressed an interest.

10. Will your company provide data rights for the blades, including manufacturing process procedures? If not, please explain why and suggest an alternate solution.

11. Reducing the costs of owning, inspecting, and / or repairing the Compressor C1 blades will likely be necessary given projected future budgets. Please provide examples of how your company successfully reduced costs for similar type blades and why that experience may be useful here.

12. What topics would you like to have discussed in future Government / contractor meetings?

Please include the following with your response:

Name and address of firm Point of contact and telephone number Business size (large or small). If small, identify category (i.e., Small Disadvantaged Business; Service- Disabled, Veteran-Owned Small Business; HUBZone; etc.)

Commercial and Government Entity (CAGE) Code Registered NAICS Code(s)

Affiliate information:

Parent company Joint venture partners Potential teaming partners

Please submit any additional comments or suggestions that you would like to share with us regarding this acquisition.

Email your responses to the AEDC Procuring Contracting Officer, Mr. Kelly Pitts, vincent.pitts@us.af.mil, by close of business on November 10, 2016. If you have any questions, you may call him at (931) 454-5174. Please note that official information regarding this acquisition will be provided by the Contracting Officer. Any information received from other sources should not be relied upon as official. Any questions / comments received from industry will NOT be posted on public websites.

AEDC will host an Industry Day to share information with respect to this RFI. The current scheduled date is October 21, 2016. Interested parties should register by October 13, 2016 by contacting Ms. Kristi Martin, Contract Specialist, at kristi.martin.6@us.af.mil or 931-454-5139. Attendees must be U.S. citizens. Due to potential space limitations, please limit your planned attendance to no more than two representatives. Detailed information for Industry Day will be posted on the FBO website in the near future.

Further information and descriptions of AEDC facilities may be found on our website www.arnold.af.mil by following the link in the center of the page under Spotlights to the Test Facilities Guide.

mailto:vincent.pitts@us.af.mil mailto:kristi.martin.6@us.af.mil http://www.arnold.af.mil/