Attachment 1 - PWS - MCHFSS 2.pdf

Exhibit A – Performance Work Statement

MECHANICAL AND COMPOSITE HARDWARE FABRICATION SUPPORT

SERVICES 2 (MCHFSS2)

1.0 INTRODUCTION

The National Aeronautical and Space Administration (NASA) Langley Research Center (LaRC) pioneers the future in space exploration, scientific discovery, and aeronautics through research and development of technology, scientific instruments and investigations, and exploration systems. The Manufacturing Applications Branch support the Engineering Directorate (ED) in meeting the vision and mission of LaRC and NASA as an Agency. The mission is met by both civil servants and a Contractor support team who cooperatively work to see our Nation’s goals are reached.

2.0 GENERAL SCOPE

This Performance Work Statement (PWS) covers the general requirements for Mechanical and Composite Hardware Fabrication Support Services (MCHFSS) . The Contractor shall design and fabricate research-oriented, one-of–a-kind flight test articles and assemblies including, but not limited to, ground support equipment, aircraft, spaceflight, laboratory, science, research facilities and instrumentation requirements in Government-provided facilities on-site at NASA LaRC. These services shall encompass functional fabrication work areas with support services provided for: Mechanical Fabrication and Composite Fabrication of research oriented hardware.

The Contractor shall, except as otherwise specified, furnish all personnel, training, transportation and on-site management necessary to perform the work. In addition, the Contractor shall utilize ISO 9001 and AS9100 during performance of tasks. On a regular basis, the Contractor shall transport material, equipment, and parts from one building to another on-site at LaRC. The Contractor shall perform work in accordance with task orders that shall include performance standards and fabrication specifications in the form of assembly drawings, sketches, and written requirements describing the work to be performed along with any special fabrication operations, procedures, and techniques required to complete the task.

The Contractor shall follow and provide documentation in accordance with the task order. Such documentation may include, but is not limited to, documentation required by NASA LaRC LMS-CP- 5640, and LMS-CP-5646, as well as redlined fabrication drawings that reflect the ‘as-built’ configuration of the final hardware.

3.0 MECHANICAL FABRICATION SUPPORT

The Contractor shall support three functional work areas: Metallic Machining, Welding, and Metal Fabrication. The Contractor shall fabricate research-oriented mechanical hardware including, but not limited to, hardware for aircraft instrumentation, aircraft structural modifications, aircraft flight test hardware, simulator modifications, modification to commercial off-the-shelf (COTS) equipment, structural test articles, and research instrumentation, ground support equipment, spaceflight applications, panels, chassis, equipment racks, instrumentation pallets, and cabinets, and research hardware within test facilities. The Contractor shall provide corrosion control, surface preparation, to include wire brushing, sanding, and other methods recommended by coating manufacturers, and application of coatings in accordance with industry standards, or as specified in the task order. The Contractor shall design and fabricate special unique tools and fixtures, and develop techniques and processes applicable to metal fabrication technologies. The Contractor shall support the development, fabrication, and testing of unique precision metal wind tunnel models, precision flight and space flight hardware including related ground support hardware, facility components, and laboratory test apparatus. The Contractor shall utilize a variety of specialized machining such as numerically controlled milling, high-speed machining, and wire electrical discharge machining. The Contractor shall operate heavy lift equipment and cranes, such as, 18- Ton mobile crane, high reach man lift, forklifts, 5 and 10 Ton overhead cranes. The Contractor shall support the development of precision models for wind tunnel tests, high-reliability instruments for space flight experiments, and intricate fixtures and support apparatus for research facilities. The Contractor shall provide support for assembly, repair, and testing of mechanical components/systems. The Contractor shall perform a full range of metals fabrication functions such as cutting, bending, precision forming, rolling, braking, and welding. The Contractor shall manage fastener, metal deliveries, and tool room operations.

The Contractor shall provide metal distribution to various locations on Center. Contractor vehicles are required to move material between buildings. Generally, full-sized trucks and cargo vans are sufficient for most material moves.

3.1 Metallic Machining - The Contractor shall perform specialized machining processes and program and operate a range of equipment, including but not limited to, programing and operating 3 axis and 5 axis Computer Numerically Controlled (CNC) mills and lathes, 4 axis wire Electrical Discharge Machining (EDM) and, multi-axis abrasive waterjets. The Contractor shall also operate conventional mills and lathes. The Contractor shall design and fabricate special unique tools and fixtures, and develop techniques and processes applicable to machining of metal alloys, polymers, and composites.

3.2 Welding - The Contractor shall perform welding techniques and processes including, but not limited to, arc welding such as Flux Cored Arc Welding (FCAW), Gas Metal Arc Welding (GMAW) also known as Metal Inert Gas (MIG), Gas Tungsten Arc Welding (GTAW) also known as Tungsten Inert Gas (TIG), and Shielded Metal Arc Welding (SHAW). The Contractor shall utilize welding procedures ,welders and welding operators qualified in accordance with ASME Section IX or appropriate AWS Standards ie: AWS D1.1 Structural Steel, AWS D1.2 Aluminum. etc and as may be specified in the Fabrication documents as approved by the WSPE (Welding Standard Practice Engineer). Inspection shall be in accordance with the applicable welding Consensus Code or as otherwise stated in the referenced fabrication document or as specified in the task order. Additionally, the Contractor shall utilize personnel with appropriate silver soldering and brazing certifications in accordance with American Society of Mechanical Engineers.The Contractor shall utilize these processes to fabricate and develop precision flight and space flight hardware including related ground support hardware, facility components, and laboratory test apparatus.

3.3 Metal Fabrication - The Contractor shall perform a variety of metal fabrication processes including, but not limited to, aviation metal-smithing; conventional and specialized machining; hand tooling and fitting; and metal cutting, aligning, shearing, punching, drilling, grinding, sawing, welding, torch-cutting, forming, bending, rolling, braking, and fastening utilizing riveting, and bolt/screw applications.

4.0 COMPOSITE FABRICATION SUPPORT

The Contractor shall fabricate research-oriented composite hardware including, but not limited to, the development, fabrication, instrumentation, and testing of precision flight and space flight composite aero-elastic and force test wind tunnel test articles. The Contractor shall provide composite fabrication support including, but not limited to, exploration hardware and test articles, free-flight, spin and dynamically scaled remotely piloted articles; planetary and lunar rovers, flight and ground support hardware, tunnel blades, display articles, crates, facility components and laboratory testing apparatus. The Contractor shall support three functional work areas: Composite Model Making, Composite Fabrication, and Instrumentation. The Contractor shall develop one-of-a-kind test specimens utilizing special fabrication techniques applicable to plastics, polymers, composites and additive manufacturing including, but not limited to, application and development of fabrication techniques in ceramics processing and foundry operations to cast and mold non-metallic models and components. The Contractor shall support real time proof-of-concept engineering model development and experimental application techniques utilizing a variety of both plastic and metallic additive manufacturing systems.

4.1 Composite Model Maker – The Contractor shall perform composite model making. The Contractor shall utilize unique processes in composites technology including, but not limited to, model making, patternmaking, mold fabrication, vacuum bagging techniques, material lay-up, polymeric applications and resin infusion. The Contractor shall utilize specialized laboratory equipment including, but not limited to, numerically controlled milling machines, high-speed routers, ply cutters, vacuum pumps, heated paint rooms, conventional wood working equipment and autoclave systems. The Contractor shall support the development and instrumentation of precision models and related structures and hardware for aerospace research. The Contractor shall provide composite surface preparation and application of coatings. The Contractor shall follow proper coatings applications and environmental standards.

4.2 Composite Fabricator – The Contractor shall perform composite fabrication. The Contractor shall utilize laboratory equipment including, but not limited to, laser trackers, Computer Aided Manufacturing (CAM) systems, additive manufacturing systems, numerically controlled milling machines, high-speed routers, ply cutters, advanced robotic fiber placement systems, heated paint rooms, conventional wood working equipment and autoclave systems to develop and instrument precision test articles and related structures, test specimens, and hardware for aerospace research applications. The Contractor shall work with a wide range of materials including, but not limited to, pre-preg, dry fabric cloths and unidirectional carbon fiber and fiberglass, release agents, and other room temperature, oven cure and autoclave processing materials. The Contractor shall perform ceramics processing and foundry operations to cast and mold non-metallic models and components. The Contractor shall utilize additive manufacturing technologies including stereolithography, fused deposition modeling, selective laser melting, and wax patterns. Additionally, the Contractor shall develop laser ablation techniques for processing unique materials not suitable for conventional processes.

4.3 Instrumentation – The Contractor shall install instrumentation in models and flight test articles to include, but not limited to, plastics, ceramics, and hybrid metals. The Contractor shall install components including, but not limited to transducers, static pressure tubes and thermocouples. The Contractor shall utilize methods of instrumentation installation including, but not limited to, bonding, brazing, soldering, molding in place, spot welding and other physical attachment techniques. The Contractor shall advise as an expert authority on a wide variety of production materials and methods related to the organization's work in instrumentation applications technology including, but not limited to, metallic test article development; composite test article development; polymeric applications; electrostatic discharge brazing and soldering; general machining, woodworking and composite fabrication applications; various surface treatments; hardware quality assurance; and other related manufacturing and processing methods used in the production of research-oriented hardware for aerospace applications.

4.4 Composite Specimen Manufacture – The Contractor shall machine and manufacture specimens utilizing advanced composite materials. Contractor shall utilize unique processes in composites technology in the machining of test specimens and manufacturing of test fixtures, using both conventional and non-conventional techniques to machine precision specimens. These specimens include, but are not limited to, tensile, compression, bi-axial, compact tension, and large stiffened compression damaged panel specimens.

The Contractor shall develop one-of-a-kind test specimens utilizing special fabrication techniques applicable to plastics, polymers and composites including, but not limited to, Spectra, graphite, carbon fiber, Avocoat and fiberglass as well as more conventional materials.

The Contractor shall utilize specialized laboratory equipment including, but not limited to, milling machines, lathes, slicers, grinders, water jets and the LabCut 5000. Machining services include, but are not limited to, diamond coated and abrasive tooling and low-stress grinding, both cylindrical and surface grinding, polishing and final dimensional inspection. The Contractor shall adhere to tolerances outlined in American Society for Testing and Materials (ASTM) standards and industry standards.

5.0 GENERAL MANAGEMENT

The Contractor shall interface with NASA and Contractor research scientists, engineers, and technicians, including Quality Assurance personnel. The only positions authorized to change contractual agreements or give technical direction are the contracting officer (CO) and contracting officer’s representative (COR) to the extent of the delegation from the CO.

The Contractor shall utilize the Government’s E2 work management system and the non-conforming requirements (NCR) system in the process of all work. The Government may upgrade or change these systems during performance of the contract.

5.1 Task Order Management System – The Government will provide a Task Order Management System for planning, organizing and controlling task order activities. The Government will provide an automated system that establishes the task flow process to ensure flexibility, responsiveness, accuracy, and archiving of the task orders. The task order automated system will allow for the electronic initiation, receiving, review, approval, issuance, and modification of task order(s). The Contractor shall track and generate end user reports to include, but not limited to, individual task order’s estimated cost, funded costs and fee, cumulative task orders estimated cost and fee; fabrication areas tasked, start, stop and completion dates, total task hours (ordered and used), and a completed task quality standard metric for customer feedback with comment input field. The system shall provide security levels to ensure it is secured and only viewable to authorized users.

The Government-provided task order management system shall be used unless otherwise approved by the Government.

5.2 Response – The Contractor shall be responsive to both routine and rapid response work order requests.

5.2.1 Routine Response – See Contract Section H.2 Task Ordering Procedures.

5.2.2 Rapid Response - The Contractor shall respond to rapid response requests by the Contracting Officer (CO) or COR. Upon receipt of a rapid response task order request, the Contractor shall provide a task order proposal for the requirement within 2 hours. Historically, there have been 1-2 rapid response requests per month with the total average of 8 hours of effort provided per request.

5.3 Progress/Program Meetings – The Contractor shall participate in reviews with the CO and NASA Engineering Directorate management to discuss cost planning, phasing and performance and the overall progress of the Contractor, subcontractors, and vendors on a daily basis, or as required by the CO. These reviews may include both formal and informal discussions with multiple customers requiring multiple products/reports, sometimes due concurrently.

5.4 Employee Certification & Training - The Contractor shall maintain certification and training records on all Contractor employees working on the contract. The Contractor shall ensure that all employees maintain required training and certifications, including but not limited to, forklift, overhead crane, and mobile crane operations and for welding, silver soldering, and brazing standards as listed in

PWS section 3.2.

Additional training may be required at the task level. Contractor-procured training shall be OSHA approved.

5.5 Training – The Government may require the Contractor to attend training and performance certifications on specific equipment or applications of particular unique procedures that are not commercially available. This additional training must be coordinated by the CO or COR.

In accordance with NPR 3410-2G, with the authorization of the cognizant CO or COR, as delegated, NASA may permit LaRC contractor personnel to attend authorized and scheduled NASA training provided that space is available and such attendance does not deny civil service employees training. The training must be necessary for Government purposes. In addition, training may be held on-site or off-site.

The following training and certifications are required, and include, but are not limited to:

Contractor-provided training

1) Weld Qualifications/Certifications as per ASME Section IX

2) Mobile Crane Operator certification

Government-provided training with certification

1) Overhead Crane

2) Fork Lift

3) Fall Protection

4) Respirator

5) Confined Spaces

6) Polymeric Certification

7) Software training certifications in

a. Powermill

b. Solidworks

c. Power Inspect

d. Verisurf

e. Esprit

8) Scaffold Erection certification Overhead Crane and Forklift qualifications are required for all employees.

However, not all Contractor employees are required to be certified in all areas listed above. Contractor employees are identified for specific training based on task order requirements. Approximately 3 to 5 Contractor employees are required to have certifications in several areas, so that the Contractor staff covers the suite of certifications required.

5.6 PERSONAL PROTECTION EQUIPMENT (PPE)

The Government will provide PPE, to include basic items, such as safety glasses, hard hats, and welding safety equipment. All other PPE shall be provided by the Contractor.

6.0 PLACE OF PERFORMANCE

The work will be performed on-site at LaRC. Other work sites may be specified at the task order level.

6.1 Government Facilities On-Site - The Government facilities have equipment available for contract performance as listed below. The Government may modify, change, reconfigure or relocate on-site performance locations without notification and approval to the Contractor.

Currently, the LaRC work sites are: Advanced Machining Facility - building 1225, Advanced Manufacturing Flight Test Article Laboratory - building 1232A, Materials Casting & Precision Specimen Laboratory – building 1237-A, Composite Model Development Laboratory -building 1238B, Hangar Annex - building 1244D, Metals Fabrication Facility– building 1245, and various research facilities, and on-board the various research aircraft.

7.0 TRANSITION OF CONTRACT SERVICES

The Government will provide access to facilities after award for transition of activities. Dates and times shall be mutually agreed upon by the Government and Contractor to minimize disruption of services.

The COR will assist with access to facilities. Office space will be provided from February 1, 2025 through March 31, 2025 for up to 2 people.

8.0 APPLICABLE DOCUMENTS

LMS- CP-5640 Requesting, Performing, and Closing Fabrication Services Request

LMS-CP-5646 Requesting, Performing, and Closing Non-Formal Fabrication Requests

Langley Form (LF) 133 Fabrication Work Request LF 211 Heat Treatment Record LPR 1440.7 LaRC Records Management Procedural

Requirements LMS-CP-4892 Bonded Storage LMS-CP-5507 Reporting and Disposition of Nonconforming

Aerospace Hardware Items and Products LMS-CP-5514 Controlled Stores LMS-OP-5641 Contractual Resource Management for Fabrication LMS-CP-5698D Welding/Brazing LF 34 Welder's Concurrency Log Entry LF 471 Weld Procedure Specification (WPS) LF 472 Welder Performance Qualification (WPQ) LF 473 Procedure Qualification Record (PQR) NPR 4200.1H NASA Equipment Management

NPR 8735.2C Hardware Quality Assurance Program Requirements for Programs and Projects

LAPD 1440.7 & LMS-CP-1440.8 Records Management

AWS D1.1 Structural Welding Code - Steel

AWS D1.2 Structural Welding Code - Aluminum AWS B2.1 Base Metal Grouping for Welding Procedure and

Performance Qualification ASME Section IX Welding and Brazing Qualifications

APPENDIX A - Definitions, Abbreviations, and Acronyms

Term Definition ASME American Society of Mechanical Engineers ASTM American Society for Testing and Materials AWS American Welding Society CAM Computer Aided Manufacturing CNC Computer Numerically Controlled CO Contracting Officer COR Contracting Officer’s Representative COTS Commercial Off The Shelf CP Center Procedure ED Engineering Directorate EDM Electrical Discharge machining FCAW Flux Cored Arc Welding GMAW Gas Metal Arc Welding GTAW Gas Tungsten Arc Welding LaRC Langley Research Center LF Langley Form LMS Langley Management System LPR Langley Procedural Requirement MAB Manufacturing Applications Branch MCHFSS Mechanical and Composite Hardware Fabrication Support Services MIG Metal Inert Gas NASA National Aeronautics and Space Administration NC Machinist Numerical Control Machinist NPR NASA Procedural Requirement On-Site Langley Research Center (LaRC) or other NASA Centers PWS Performance Work Statement similar to a Statement of Work and used synonymously Response Having Contractor personnel working on-site at the NASA LaRC facility Rapid Response An unexpected occurrence or set of circumstances demanding immediate action at the discretion of the CO or COR outside the normal work hours (Monday thru Friday 7:00 am – 4:30 p.m.)

SHAW Shielded Metal Arc Welding TIG Tungsten Inert Gas WSPE Welding Standard Practice Engineer