EPSE_II_TO2_task_PWS_(Cold_Spray)_v1_Final.docx

Enterprise Product Support Engineering Initiatives

Cold Spray Efforts

IDIQ GSA ITSS IDXXX

1 Sep 17

TASK ORDER: 002

Air Force Life Cycle Management Center (AFLCMC) Product Support Engineering Division (EZP) Department of the Air Force Wright-Patterson Air Force Base (WPAFB), OH

POCs:

Program Manager:

Jesse Holdaway, AFLCMC/EZP Phone: (937) E-mail: jesse.holdaway@us.af.mil

COTR:

Greg Schwabacher Phone: (937) 656-7903 Fax: (937) 255-7791 E-mail: gregory.schwabacher.1@us.af.mil

GSA:

Theresa Vollink Phone: (312) 279-8145 Fax: (312) 886-3827 E-mail: theresa.vollink@gsa.gov

1. BACKGROUND: The Air Force Life Cycle Management Center Product Support Engineering Division (AFLCMC/EZP) was established to ensure the USAF tackles product support engineering problems using an enterprise approach crossing multiple platforms and portfolios. AFLCMC/EZP’s primary customer base includes the Program Executive Offices (PEOs), System Program Offices (SPOs) – Chief Engineers, Air Force Sustainment Center (AFSC), Major Commands (MAJCOMs), as well as other center offices and headquarters. The USAF realizes that coordinated efforts progress faster and cost less in total and that moving in consistent pathways is critical to making the changes required to bend the cost curve and increase readiness.

As the USAF progresses towards a cost effective engineering mindset, opportunities to implement agile technologies such as cold spray across the USAF enterprise must be considered and evaluated to improve sustainment parts availability, reduce life cycle costs and increase weapon system readiness. The Air Force plans to implemented an Cold Spray Strategic Implementation Plan that uses an enterprise approach to design, qualify, and repair worn components using various types of cold spray technologies. In order to address the challenges associated with implementing this new technology, standard processes and procedures, tools, and equipment are required. In addition, material properties are also required to be developed and documented to allow family of part repairs.

2. SCOPE OF WORK: The scope of this Task Order is to develop and validate standard design and qualification procedures to repair aerospace components, tooling, fixtures using various low pressure and high pressure cold spray technologies that also follow the tenets of an airworthiness risk assessment. Work under Task Order 002 will cross multiple Program Executive Offices (PEOs) and System Program Offices (SPOs) using an enterprise approach; the Contractor shall:

· Develop and deliver one standard process order for technicians and/or engineers to design, repair and qualify components using cold spray technology.

· Develop and deliver a Cold Spray Design Rules Guidebook for engineers that includes:

· Process parameter settings for both the recommended cold spray machine and associated powder(s) that provides the design engineer the material properties achieved for these specific settings

· Process parameter settings for each material shall be optimized for aerospace applications and should include post process requirements

· Cold spray design rules required to achieve material properties and required surface finish

· Cold spray manufacturing rules to achieve required properties for the part to include post processing requirements

2.1. Objective. The overall objective of this Task Order is to develop and deliver standard processes and procedures to design, repair and qualify components using cold spray technologies. To accomplish this objective, the Contractor will be required to provide program management, plans, schedule, cost, mechanical/material/environmental testing, analysis, and documentation using the Air Force airworthiness risk assessment approach called out in AWB-1015.

3. CONTRACTOR REQUIREMENTS: The Contractor shall be required to develop detailed test plans to optimize parameter settings for the cold spray machine and powder and provide analytical capability for material testing and analysis. Capture all process results and analysis in detailed final reports. All data generated (including raw data) shall be delivered to the Air Force as part of the test reports.

Each Task Order requirement shall be funded based on the availability of resources. Under this Task Order, multiple activities/parts must be simultaneously managed. To execute this Task Order, both technical and program management activities shall be required, and the Contractor shall apply common technical and program management oversight, tools, and requirements and techniques. In all cases, the Contractor shall perform the appropriate level of effort in accordance with the state of the technical activity (i.e., some deliverables may require in-house cold spray design, in house spraying/repair, post processing, testing, analysis, demonstration, and validation support while others will require management of sub-tier suppliers whereby planning and requirements matching to ensure sub-contractor contract deliverables are the critical activities required). For this Task Order, the Contractor shall consider, as appropriate, program management requirements, environmental, energy and safety requirements/savings, readiness factors, return on investment, and sustainment/maintenance needs associated with each part. Each effort shall have a program schedule, program objectives, test plan/approach and a final report that includes all raw data, technical and non-technical, technical reports and analysis. In-process program reviews shall be required. Data shall include raw data, notebooks, pictures, analysis, test plans, Design of Experiments (DOE) results, modeling, analytical data and test results, computer generated data and programs as well as any data that is used to determine technical and programmatic information and decisions. The Contractor, or their subcontractor shall propose a program manager for the technical activity as well as subject matter experts, as required, to lead technical activities. All team members shall also be identified and approved by EZP. Listed below are some of the major technical activities to be accomplished. Each activity/demonstration part must be considered a separate undertaking and deliverable if funded. Monthly reporting shall be conducted that includes status on technical performance, cost and schedule aspects as well as a detailed invoice for each sub-task. The Contractor shall also develop a parent-level program plan and integrated master schedule that outlines all technical activities, showing any interconnects between efforts as means to enhance efficiencies and effectiveness.

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3.1. Standard Cold Spray Process Order. The Contractor shall propose a plan for development and management of standard cold spray process order(s). The Contractor shall propose either one or multiple cold spray process orders that would provide technicians and engineers detailed methodology for designing, repairing, and when necessary qualifying repair of various components. The Contractor shall develop and deliver the first draft of a standard, digital cold spray process order(s) for technicians and engineers to design, repair, and qualify (when necessary) tooling, fixtures, and components for various types of materials and cold spray technologies. Process orders should contain all steps and paper work (forms) required for certification of the process, configuration control, repeatability, data analytics for quality control, and requirements for equipment check-out.

3.2 Cold Spray Design Rules Guidebook. The Contractor shall develop and deliver a digital Cold Spray Design Rules Guidebook (Version 1) for technicians and engineers that includes:

3.2.1 Material Properties. The Contractor shall develop and deliver optimized process parameter settings for the VRC machine for three different metal powders. The Contractor shall recommend three different powders for this effort. The Contractor shall provide the rationale for the recommended powders (and vendor(s)) and the proposed methodology for optimizing parameter settings. The Contractor shall develop and obtain AF approval for a test plan to execute the optimization of parameter settings, execute the test plan and provide all test results, analysis, and recommendations for the recommended optimized parameters that will be utilized for design using each powder. In addition, the Contractor shall develop a set of material properties for the optimized parameter settings and the recommend post processing steps to achieve optimized material properties for each of the three powders. The material properties for each powder and associated design rules to achieve the material properties shall be provided and delivered to the Air Force in the cold spray design rules guidebook. The Contractor shall develop a test plan to obtain material properties. The test plan shall be approved by the Air Force before printing and testing begins. The Contractor shall propose recommended testing, location for material testing, analysis, and consolidation of test results to develop the material requirements database. In the proposal, the Contractor shall propose key considerations for printing/testing to gather high confidence data. All raw results/data, analysis and recommendation will be provided to the Air Force in interim test reports for each powder. A final digital test report shall be delivered to the Air Force consolidating all testing, results, analysis, pictures, modeling results, and recommendations.

3.2.2 Design and manufacturing requirements. The Contractor shall develop and continuously update a list of design and manufacturing considerations (rules) required to achieve successful repairs with the material properties in 3.2.1. In addition, the design and manufacturing rules should take into consideration all critical requirements necessary to ensure repeatability is achieved from repair-to-repair. All required tools, skill sets, and requirements will also be included in the Cold Spray design rules guidebook. A database of all design rules and all manufacturing rules will be developed, updated, and maintained by the Contractor through the period of performance. The most current version of the database will be delivered to the Air Force at the end of the contract. All test data, results, pictures, lessons learned, and analysis to achieve repeatability will be delivered to the Air Force in a final report. All manufacturing requirements to include (as a minimum) operator skill sets, equipment, equipment configuration, maintenance, configuration control and storage of powder and configuration of equipment shall be documented and best practices will be developed to ensure stability of operations and repeatability is achieved. “Crash” reports will be developed for any repairs that do not perform as planned and detailed analysis will be performed and documented to determine root cause. All analysis will be documented in a lessons learned database and best practices will be developed based on successes and lessons learned. An all-inclusive lessons learned and best practices database will be delivered to the Air Force. Best practices and lessons learned will be incorporated into the Cold Spray Design Rules Guidebook. Considerations for both design and manufacturing rules will be included.

3.2.3 Communication. Communicating lessons learned and best practices, “tips and tricks” on Cold Spray is a key tenet of successful technology transition and implementation across the AF enterprise. The Contractor shall develop and execute a communication plan to gather and share best practices and lessons learned across the AF enterprise. The Contractor shall propose a draft approach with their proposal outlining methodologies and their proposed approach to both gather and cross-share information on Cold Spray.

The Contractor shall complete all aspects & components laid out within the scope. The Contractor shall accomplish tasks in accordance with AWB-1015, as required. The Contractor shall provide adequate support towards all efforts, as required to complete the tasks. All raw and summarized data, test results, drawings, pictures, modeling, analytics, process orders, methodologies and coding shall be unrestricted and submitted electronically with final test reports, provided to the AF in Microsoft Word, Excel, and PowerPoint presentation formats. All final reports shall be presented to the Air Force through in-person briefings summarizing all results and recommendations as well as final documented reports. Any deviations to the PWS scope shall be approved by the government PM and contracting officer. All papers, briefings, results, tours, videos provided and developed by the Contractor shall be approved by the Air Force and must be approved for public release.

4. DELIVERABLES:

Data Item Title

Description

Due Date

5. MEETING ATTENDANCE/TRAVEL: Travel to commercial vendor sites, test facilities and military installations is expected. The Contractor shall abide by all Air Force safety and conduct policies when conducting travel. The Contractor shall coordinate with AFLCMC to ensure the proper Government documentation is in place, such as CAC cards and/or clearances pending the type of efforts and programs the Contractor is asked to support. Throughout the period of performance, the Contractor shall coordinate all efforts directly with AFLCMC/EZP personnel and the contracting officer; this includes any travel requests, equipment purchases and the level of effort per month that shall be allocated to this support. The Contractor shall report all findings, recommendations, and efforts thru travel reports to EZP personnel, as appropriate. All travel requires a trip report outlining discussions and results from the trip. The Contractor shall participate in regular progress meetings and travel to events deemed necessary to provide support efforts described above. It is anticipated that travel to USAF sites including, but is not limited to:

· Wright Patterson Air Force Base, Ohio

· Eglin Air Force Base, Florida

· Hill Air Force Base, Utah

· Robins Air Force Base, Georgia

· Tinker Air Force Base, Oklahoma

5.1. Kick-Off Meeting. Within 15 days of award, the Contractor shall coordinate an Overall Task Order kickoff meeting, at which time all parties involved in the Task Order execution shall be represented and roles/responsibilities clearly outlined. During the kickoff meeting, the Contractor shall be prepared to discuss the Task Order at the parent level as well as details for each technical activity. In addition, individual technical activity area kick-off meetings shall occur for every funded area. The intent of the technical activity area kick-off meeting is to review the sub-task schedule, objectives of each technical activity area, and review roles and responsibilities of the players.

5.2. Meetings. The Contractor shall plan to participate in monthly and quarterly progress meetings, detailing the progress, issues, needs, and/or unforeseen items that occur. The Contractor shall be responsible for coordinating and scheduling all meetings; however, the government PM shall maintain approval authority for date, time, and location of all meetings. The Contractor shall prepare an agenda, briefing materials, brief project status and technical data, and coordinate in advance of any meeting for government PM approval. The government PM has authority to attend or not attend any scheduled meetings. The Contractor shall capture and track all action items, decisions, and minutes from all meetings and telecoms. A detailed review of each technical activity area shall be required.

6. GOVERNMENT FURNISHED EQUIPMENT: No government furnished equipment will be provided. The proposal shall include a preliminary list of equipment required by the Offeror to complete the effort under this task. The preliminary list should include any equipment (cold spray equipment, robotics, spray booth and post-processing equipment), software, tools, powder, gas and/or testing apparatus over $25,000. A rationale for the equipment, tools, powder, gas and/or testing apparatus is required.

7. PLACE OF PERFORMANCE: The Contractor shall provide a location or locations to operate an AFLCMC Additive Manufacturing (AM) & Cold Spray Innovation Center(s) near Wright Patterson Air Force Base, Ohio. All work will be accomplished at the AFLCMC Innovation Center(s). Future AFLCMC AM and Cold Spray Innovation Centers may be established at other locations. None of this work will be accomplished on an AF installation. The size of the Innovation Center(s) should accommodate potential future task orders as well.

8. SECURITY CLASSIFICATION: None

9. PERIOD OF PERFORMANCE: 12 Months.

10. SPECIAL INSTRUCTIONS: None