LAWS Fixture Final SOW.pdf

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Statement of Work

For

Fabrication of Loader, Reactor and Wingbox for Large Airframe Wing Structure (LAWS) Test Fixture

Federal Aviation Administration William J. Hughes Technical Center for Advanced Aerospace

Structures & Materials Section, ANG-E281 Atlantic City, New Jersey 08405

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1. OVERVIEW:

The Structures and Materials Laboratory (SML), located at the Federal Aviation Administration (FAA) William J. Hughes Technical Center, was officially opened in December 2016 as a new home for advanced material and structural test capabilities. The intent for the lab, once fully operational, is to house multiple uniaxial test frames and space to conduct full-scale aircraft structural component tests simultaneously on an integrated system. This will allow the FAA Technical Center to execute research programs in support of FAA Aviation Safety (AVS) with their core mission functions of aircraft certification, continued airworthiness, rulemaking, policy and guidance development and training. This statement of work (SOW) will provide for a fully functioning structural test capability to test full-scale wings.

2. BACKGROUND:

In partnership with the Boeing Company, a new structural test capability referred to as the Large Airframe Wing Structure (LAWS) fixture is under development within the Federal Aviation Administration’s (FAA) Structural and Materials Lab (SML) for configured wing panel testing.

The LAWS fixture, shown in Figure 1 is a self-reacting structure designed for fatigue and residual strength testing of flat panels, 152” in length by 60” in width. The fully integrated system will consist of the mechanical fixture, hydraulic components, and control and data acquisition systems.

Four 200Kip hydraulic actuators will be used to apply in-plane and out-of-plane shear, bending moment, and torsional loading to maximum strain range of ±10,000 µε.

Initially, the LAWS fixture will be used to support the bonded repair program also in collaboration with the Boeing Company. The program objectives are to characterize the fatigue and damage tolerance performance of bonded repairs subjected to simulated service load (SL) conditions and to evaluate the residual load capability of a typical composite wing panel of transport category aircraft with intact, partially failed, and fully failed repairs. Emphasis has been placed on investigating methods and tools used to conduct analysis and performance predictions of failed bonded repairs as well as those used to monitor and evaluate repair quality over the life of the part.

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Figure 1. Schematic of LAWS fixture

3. OBJECTIVE:

The objective of this SOW is to fabricate major components of the LAWS fixture, specifically, the Reactor (SA3), Wingbox (SA4) and Loader (SA5) parts. For this, the vendor must: 1.

procure the raw material; 2. machine the parts per the engineering drawings in Appendix A; 3.

weld the components per instructions provided in Appendix B; 4. perform post weld heat treatment; 5. perform final machining, drilling holes and surface finish, and; 6. ensure the alignment of holes and assembly of the these three components.

The basic details of parts, materials, finished dimensions and minimum stock size of the raw material is provided in Table 1.

Table 1. Details of parts material, dimensions, and minimum raw material stock size

Compon ent

Part Name/Number Material Quantity Finished Dimensions (in)

Raw material minimum stock size (in)

Estimated Weight (lbs.)

Reactor

(SA3)

Reactor Top Plate, SA3-P1

ASTM

A514 Grade S

1 110 x 60 x

3.6069 112 x 62 x 4 7,861

Reactor Side Beam, SA3-P2

2 110 x 8.559 x

112 x 11 x

1.5 1,046

Reactor Bottom Plate, SA3-P3

1 110 x 60 x 2.25

112 x 62 x

2.75 5,404

Reactor Tors Box, SA3-P4

2 52.5 x 8.559 x 1 55 x 11 x 1.5 514

Loader

(SA5)

Loader Top, SA5-P1 ASTM A514 Grade S

1 141 x 60 x

3.607 143 x 62 x 4 10,036

Loader Side Wall, SA5-P2

2 141 x 8.559 x

143 x 11 x

1.5 1,335

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Loader Bottom Plate, SA5-P3

1 141 x 60 x

2.25 143 x 62 x 3 7,527

Loader Torsion Close, SA5-P4

2 52.5 x 8.559 x 1 54 x 10 x 1.5 458

Bearing Block, SA5- P6

4 8.559 x 8.559 x 3.25 10 x 10 x 4 453

Wingbox

(SA4)

Alignment Panel, SA4-P1

Plate Section 1

Aluminum T7451 or 7075 T651

1 76.940 x 60 x

0.75 79 x 62 x 1 495

Plate Section 2

1 75 x 60 x 0.75 77 x 62 x 1 482

Splice Plate

2 44 x 12 x 1 46 x 14 x 1.5 195

Panel Spacer

2 55 x 21 x

2.9423 57 x 23 x 3.5 927

Wingbox Shim

2 60 x 13.25 x 0.08

60 x 13.5 x

0.08 13

Side Channels, SA4- P2 Pultrusion

Fiberglass

20 feet stock supplied by

FAA

Bottom Plate, SA4-P3

Normalized Steel

1 152 x 60 x

2.25 154 x 62 x 4 10,808

Top Outside Splice 2 60 x 30.5 x 1 62 x 32 x 1.5 1,684 Top Inside Splice, SA4-P5

2 54 x 30.5 x 1 56 x 32 x 1.5 1,521

Bottom Outside Splice, SA4-P6

2 60 x 30 x 1.5 62 x 32 x 2 2,246

Bottom Inside Splice 2 52 x 30.5 x 1.5 54 x 32 x 2 1,956

Spacer, SA4-P8 2 152 x 2 x 1.5 154 x 4 x 2 697

4. SCOPE OF WORK:

The scope of work is defined in sections 4.1 – 4.2 below:

4.1. The awarded company must have Computer Numerical Control (CNC) machines capable of machining ASTM 4340 and A514 steel plates (up to 154 inches x 62 inches x 4.5 inches) in dimensions and drilling holes with positional and size tolerance of 0.005 inches in about 15,000 lbs. welded assemblies along 154 x 60 inches area. The company must also have the expertise and certifications to weld large (up to 141 inches x 60 inches x 3.6 inches) A514 plates and surface finish =< 250 micro inches and worst-case flatness of .05 inches over longest part dimension. In addition, the vendor must have the capability to check all the hole locations with laser and be able to assemble all the components together to check hole alignments. The contractor must deliver to the FAA Reactor (SA3), Wingbox (SA4) and Loader (SA5) components in ready-to-be-assembled condition. The requirements are provided in Table 2 and section 4.2.

Table 2. Details of Tasks and Requirements for components fabrication Task # Task Requirements 1 Reactor (SA3) fabrication as per drawings in appendix A,

1. Procure raw material

2. Descale and pre-machine individual parts

07/14/25 5 welding instructions in appendix B and general requirements in sections 4.2.

3. Surface finish individual parts as per specification

4. Fabricate and weld the parts as per the requirement

5. Post weld heat treat for stress relief

6. Final machine of holes and weldment

7. Final surface finish

2 2a. Wingbox (SA4) fabrication as per drawings in appendix A and general requirements in sections 4.2.

1. Procure raw material. Side channels (SA4-P2) raw material will be provided by the FAA

2. Descale and machine individual parts

3. Surface finish individual parts as per specification

2b. Alignment Panel (SA4-P1) fabrication as per drawings in appendix A.

1. Procure raw material

2. Descale and machine the parts to size

3. Drill holes as per specification.

4. Surface finish the top and bottom at both ends of the panel

3 Loader (SA5) fabrication as per drawings in appendix A, welding instructions in appendix B and general requirements in sections 4.2.

1. Procure raw material

2. Descale and pre-machine individual parts

3. Surface finish individual parts as per specification

4. Fabricate and weld the parts as per the requirement

5. Post weld heat treat for stress relief

6. Final machine of holes and the weldment

7. Final surface finish

8. Line bore the required holes as per the requirements

9. Fit check crossbars, SA4-P5 (supplied by FAA)

4 SA3, SA4 and SA5 alignment and fit check

1. The assembly alignment and fit check must be performed at room temperature.

2. Clamp both ends of Wingbox Bottom Plate (SA4-P3) with Reactor Bottom Plate (SA3-P3) at one end and Loader Bottom Plate (SA5-P3) at the other with Inside and Outside Bottom Splice Plates (SA4-P6 and SA4-P7). Check the alignments of all 60 holes with dowel pins and ensure that pins go through the holes of stacked plates without any trouble.

3. Place and clamp the bottom flanges of two Side Channels (SA4-P2) at the two sides of Wingbox Bottom Plate (SA4- P3) and check alignments of all 45 holes with dowel pins.

4. Clamp both ends of Wingbox Alignment Plate (SA4-P1) with Reactor Top Plate (SA3-P1) at one end and Loader Top Plate (SA5-P1) at the other with Inside and Outside Top Splice Plates (SA4-P4 and SA4-P5). Check the alignments of all 165 holes on both ends with dowel pins and ensure

07/14/25 6 that pins go through the holes of stacked plates without any trouble.

5. Clamp the top flanges of two Side Channels (SA4-P2) at the two sides of Wingbox Alignment Panel (SA4-P1) and check alignments of all 45 holes with dowel pins.

6. Check the level of the assembled components.

4.2. The general requirements for each component are as follows:

4.2.1. All steel must be processed to remove scale and decarb surface coatings.

4.2.2. All parts rough cut to a minimum of 2 inches oversize in length and width from supplier.

4.2.3. All parts must be machine finished on all sides and surfaces.

4.2.4. All parts must have the machine roughness =< 250 micro inches and worst case flatness of .05 inches over longest part dimension.

4.2.5. Crossbars (SA5-P5) and Side channels (SA4-P2) will be provided by the FAA.

4.2.6. Utilize Welding Procedure Specification (WPS) written by a qualified Welding

Engineer and/or Certified Welding Inspector (CWI).

5.0 DELIVERABLES:

Required services for individual components and parts are listed in section 4. The government acceptance criteria are based on each part’s specifications detailed above and fit and alignment of the three components together. All work is expected to be complete and delivered to the Technical Center within 90 calendar days from the date of award.

6.0 PERIOD OF PERFORMANCE:

The period of performance will be 90 calendar days from Date of Award.

7.0 SHIPPING:

All shipping costs must be a Not-To-Exceed (NTE) amount and included as a separate line item in the vendor’s total proposed price as a NTE amount. A bill of lading/receipt will be required to be submitted with invoices. Only actual shipping charges will be reimbursed up to the NTE amount.

8.0 TRAVEL:

Contractor will not be reimbursed for travel as a separate line item. All travel costs must be included in the vendor’s total proposed price as a firm fixed price.

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3.6.4-5 FAA Buy American Preference - Steel and Manufactured Goods (April 2022)

CLAUSE:

(a) Section 9129 of the Aviation Safety and Capacity Expansion Act of 1990 (Subtitle B of Title IX of Pub. L. 101-508, the Omnibus Budget Reconciliation Act of 1990) requires the use of steel and manufactured goods produced in the United States when a project such as that covered by this contract receives funding.

(b) The Contractor must deliver only steel and manufactured goods produced in the United States.

This requirement will not apply where the FAA Acquisition Executive (FAE) or his or her designee has found—

(1) That its application would be inconsistent with the public interest;

(2) That such materials are not produced in the United States in sufficient and reasonably available quantities or of satisfactory quality. In accordance with AMS Guidance T3.6.4A.2 b(2), if the request is based on the steel and manufactured goods not produced in the U.S. in sufficient and reasonably available quantities or of a satisfactory quality, the use of the proposed foreign construction material must be approved by the FAA Acquisition Executive (FAE) and reviewed by the Office of Management and Budget (OMB) Made in America Office (MIAO);

(3) For facilities and equipment (F&E) funded acquisitions under AMS Guidance

T3.6.4A.1.c(2)-(4)-

(i) the cost of components and subcomponents which are produced in the United States is more than 60 percent of the cost of all components to be delivered under this contract with labor costs involved in the final assembly not included in calculating the cost of components, and

(ii) final assembly of the facility or equipment to be delivered under this contract has taken place in the United States; or

(4) That inclusion of domestic material will increase the cost of the overall contract by more than 25 percent.

(c) This clause takes precedence over the provisions of clause "Buy American Act--Supplies" and clause "Buy American Act--Construction Materials" in respect to their applicability to steel and manufactured goods.

(d) The offeror warrants that steel and manufactured goods to be used in the project are produced in the United States, and that components of unknown origin are considered to have been produced or manufactured outside the United States. Should any end product be of foreign origin, the Contractor must identify, in writing, such goods and country of origin to the Contracting Officer prior to contract award. Such information is required in implementation of Section 9129 of the

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Aviation Safety and Capacity Expansion Act of 1990, (Subtitle B of Title IX of P. L. 101-508, the Omnibus Budget Reconciliation Act of 1990).

(End of clause)