JA00437 SPRDL122R0083_Redacted.pdf

SPRDL1-22-R-0083 (JA-00437)

Previous J&A: SPRDL1-18-R-0083 onto the piston are then transferred through the connecting rods and transferred to the crankshaft assembly giving the AVDS-1790 8CR its power output capabilities. The approved sources, L3 Technologies Inc. and Tecmotiv (USA) Inc., have proven the ability to manufacture the connecting rods which can successfully meet the North Atlantic Treaty Organization (NATO) requirement for successful completion of NATO Laboratory Test for Gas Turbine Engines AEP-5, Allied Engineering Publication while operating on an AVDS-1790 8CR Engine. This test is required for components that are critical for engine/vehicle operation and crew safety. Malfunction of the AVDS-1790 8CR diesel engine due to poorly manufactured connecting rods could result in significant loss of equipment and life due to fire caused by a cracked engine block due to a 'thrown' connecting rod as a result of structural failure or by failure due to inaccurate geometries of either the crankshaft or piston wrist-pin ends of the connecting rod. Both failure modes will result in the vehicle’s inability to move the crew to safety under power. The approved sources have proven that they are able to deliver connecting rods of sufficient quality in support of the AVDS-1790 8CR diesel engines. If another possible source of supply for this item was identified, qualification testing would be required.

A fully developed, build-to-print Technical Data Package (TDP) for the connecting rods is not available. Only L3 Technologies, Inc. and Tecmotiv (USA), Inc. have the experience and capability to manufacture connecting rods that can withstand the 400-hour NATO endurance test within an AVDS-1790 8CR Engine. A reverse engineering effort to develop a fully mature TDP is estimated to cost $1.7M and would require 24 months to develop. Additionally, testing of the reverse engineered connecting rods would require successful completion of the 400-hour NATO and vehicle level durability testing required to prove out the technical data. If manufactured by a new source, the required vehicle level testing is estimated at $3.28M (Reliability, Availability, and Maintainability (RAM), NATO 400-hour, Full Load Cooling and Cold Test) and will take approximately 32 months to complete without any major issues. These estimated costs were derived from historical vehicle testing efforts and similar reverse engineering efforts within the US Government.

A cost estimate breakdown is as follows:

Reverse Engineering Effort:

Obtain sample set of quantity of 24 connecting rods: $47K Obtain two AVDS-1790 8CR Engines for 400-hour dynamometer testing: $880K Technical data development: $200K Tear down and Rebuild two 8CR engines with prototype connecting rods: $100K Design activity: Prototyping, Integration, Test: $200K NATO 400-hour dynamotor test: $250K

Vehicle Level Qualification RAM Testing of 5,000 miles: $750K Full Load Cooling Test: $282K Cold Test: $2.25M Total: $4.96M

SPRDL1-22-R-0083 (JA-00437)

Previous J&A: SPRDL1-18-R-0083 modified to meet the Government's needs. While these two sources have the ability to manufacture connecting rods for diesel applications that could theoretically be used as solutions in the M88 AVDS engines, their existing connecting rods are not specifically tailored to the crankshaft journal diameter and are not the required length unique to the AVDS-1790 8CR air-cooled diesel application. Finally, since neither of these sources have produced this specific item for the M88, they have not completed the necessary testing to become a qualified source.

Keyword: Connecting Rod Manufacturer for Diesel Engines

Website: https://www.cp-carrillo.com/pt-3508-rods.html Findings: No solutions found specific to AVDS-1790. One suitable for the AVDS-1790 would need to be developed.

Website: https://www.hatz-diesel.com/en/products/components/connecting-rods/ Findings: Application Specific. Must be developed.

9. Interested Sources: To date no additional sources have expressed interest in this item.

10.Other Facts: Procurement History:

SPRDL1-18-C-0194

Brighton Cromwell (3NNX8), Former Distributor for L3 Technologies, Inc.

$204,020.11 Competitive Status: FAR 6.302-1, Only One Responsible Source and no other supplies or services will satisfy requirements.

SPRDL1-17-P-0184

Brighton Cromwell (3NNX8), Former Distributor for L3 Technologies, Inc.

$59,305.35 Competitive Status: FAR 13.106-1(b) Single Source

SPRDL1-16-C-0121

L3 Technologies, Inc. (02978) $181,944.00 Competitive Status: FAR 6.302-1, Only One Responsible Source and no other supplies or services will satisfy requirements.

SPRDL1-15-P-0201

L3 Technologies, Inc. (02978) $111,800.00 Competitive Status: FAR 13.106-1(b) Single Source

11. Technical Certification: I certify that the supporting data under my cognizance which are included in the justification are accurate and complete to the best of my