Attachment_B,_WFIRST-IC-SPEC-0046-.pdf

Effective Date: July 10, 2019

National Aeronautics and Space Administration

Goddard Space Flight Center Greenbelt, Maryland

WFIRST-IC-SPEC-0046, Revision-

Wide Field Infrared Survey Telescope (WFIRST), Code 448

Instrument Carrier (IC)

Flight Structure Fabrication

Specification (SPEC)

GSFC WFIRST CMO

July 11, 2019

Released

Instrument Carrier (IC) Flight Structure Fabrication WFIRST-IC-SPEC-0046, Revision-ii

Instrument Carrier (IC)

Flight Structure Fabrication

Statement of Work (SOW)

Review/Signature/Approval Page

Prepared by:

Wes Alexander

Approved by:

David Content iii

Preface

This document is a Wide Field Infrared Survey Telescope (WFIRST)

Configuration Management (CM)-controlled document. Changes to this document require prior approval of the applicable Configuration Control Board (CCB) Chairperson or designee.

Proposed changes shall be submitted to the WFIRST CM Office (CMO), along with supportive material justifying the proposed change.

In this document, a requirement is identified by “shall,” a good practice by “should,” permission by “may” or “can,” expectation by “will,” and descriptive material by “is.”

Questions or comments concerning this document should be addressed to:

WFIRST Configuration Management Office

Mail Stop 448

Goddard Space Flight Center

Greenbelt, Maryland 20771 iv

Change History Log

Revision Effective Date Description of Changes

(Reference the CCR & CCB/ERB Approval Date)

Rev- July 10, 2019 Initial Release per WFIRST-CCR-0051 v

Table of TBD’s/TBRs/TBSs [optional]

Item No. Location Summary Individual/

Organization

Actionee

Due Date

0001 Sections 3 and 4 These would be test plans for secondary items

543 By IC CDR vi

Table of Contents

1 INTRODUCTION

1.1 Purpose

1.2 Scope

1.3 Background

1.4 Related Documentation

1.4.1 Applicable Documents and Drawings

1.4.2 Reference Documents

Standard Test Method for Flatwise Tensile Strength of Sandwich Constructions

1.5 Order of Precedence

2 REQUIREMENTS

2.1 Material Process Requirements

2.1.1 Process Control

2.1.1.1 Workmanship

2.1.2 Material Requirements

2.1.2.1 Pre-impregnated (prepreg) graphite cyanate-ester material

2.1.2.1.1 Material lot Acceptance Test

2.1.2.1.1.1 Tube Laminate

2.1.2.1.1.2 Gusset Laminate

2.2 Outgassing

2.3 Concurrent Process development

2.4 Process Control Requirements

2.4.1 Cured laminate

2.4.2 Primed Parts

2.4.3 Adhesive

2.4.4 Non Destructive Examination (NDE)

2.4.5 Machining Process

2.4.6 Thermal conditioning

2.5 Fabrication Process Development Requirements

2.5.1 Square Section Tube Development

2.5.2 Diamond Section Tubes

2.5.3 Double Lap Shear Test Articles

2.5.4 Adhesive Control

2.5.5 Spot bonding Process for Adhesive Control

2.5.5.1 Lap Shears Spot bonding Test

2.5.6 Plexi-glass Trials for Spot Bonds

2.5.7 Process for Adhesive Shape Control

2.5.8 Additional process verification for Adhesive lot differences

2.5.9 Process verifications for variation in adhesive mixes

2.5.10 Clip injection process

2.5.10.1 Click Bond Fastener Component and Bond Strength Test

2.5.11 Repair Tubes and Remove Clips or Bonded Joints

2.6 Development Test Assemblies

2.6.1 Higher Order Joints (Plug Joint, Double T, and Diagonal)

2.6.2 Subscale Test Articles

vii

2.6.3 Subscale Testing of Subscale Test Articles

2.6.4 Additional Plug test articles

2.6.5 Clip testing

2.6.6 Electrical Ground Test Articles

2.7 INSPECTION and VERIFICATION REQUIREMENTS

2.7.1 Responsibility

2.7.2 Material Traceability

2.7.3 Non-Destructive Examination (NDE) Requirements and Defect Acceptance

2.7.4 Assembly Weight

2.7.5 Individual Test Assemblies Inspections

2.7.6 IC Structure

2.7.7 Contamination

2.8 Quality Provisions and Test Methods Matrix

2.9 Packaging and Transportation

2.10 Cleanliness

2.11 Packaging

2.11.1 Development Test Assemblies

2.11.2 IC Flight Structure

2.11.3 Spares

APPENDIX A ABBREVIATIONS AND ACRONYMS

List of Figures

Figure 1. Flight Structure Fabrication Specification Flow-down Figure 2. Double Lap Shear example

List of Tables

Table 1. Tube Laminate Tests Table 2. Gusset Laminate Tests

Table 3. Square Development Tube Tests Table 4. Diamond Tube Tests Table 5. Quality Assurance Provisions

1 INTRODUCTION

1.1 Purpose

This specification covers performance and manufacturing requirements for Instrument Carrier (IC)

Flight Structure and subscale development test articles. The Contractor is responsible for the all requirements within this specification.

1.2 Scope

This Specification (SPEC) sets the technical requirements required to be met by the Contractor for the work outlined in WFIRST-IC-SOW-0001 which will be delivered to Goddard Space Flight Center

(GSFC). This SPEC covers both development test assemblies, and IC structure Flight unit.

1.3 Background

The IC structure design concept consists of a bonded truss frame assembly, incorporating square

Graphite Fiber Reinforced Plastic (GFRP) tubes, gusset plates, large titanium plug joints, and titanium shear clips. The baseline composite materials are Hexcel’s M55J/954-6 and T300/954-6 prepreg. The IC structure requires predictable and repeatable thermal distortion from room temperature to 170 Kelvin.

1.4 Related Documentation

The latest versions of all documents below should be used. WFIRST documents can be obtained from

URL: https://ipdtdms.gsfc.nasa.gov.

1.4.1 Applicable Documents and Drawings

The documents listed below are applicable to this SOW, to the extent specified herein, and apply directly to the performance of the IC Flight Structure contract. These documents establish detailed specifications, requirements, and interface information necessary for the performance of the contract.

In the event of conflicting requirements between this SOW and the Applicable Documents, the

Contractor shall immediately notify the GSFC Contracting Officer’s Representative (COR) of the conflict and request direction from the Government as to how to proceed.

Document Number Title

NASA-STD-5005 Standard for the Design and Fabrication of Ground Support

Equipment

NASA NPR 6000.1 Requirements for Packaging, Handling and Transportation for

Aeronautical and Space Systems, Equipment and Associated

Components

540-PG-8700.2.1 Design and Certification of Dollies, Stands, and Shipping

Containers

WFIRST-IC-LIST-0023 Instrument Carrier Flight Structure Deliverable Items List and

Schedule (DILS)

WFIRST-SYS-PLAN-

WFIRST Contamination Control Plan

WFIRST-SMA-REQ-

WFIRST Mission Assurance Requirements Document (MAR) https://ipdtdms.gsfc.nasa.gov/

WFIRST--IC-SOW-0001 Instrument Carrier, Flight Structure Statement of Work

WFIRST-IC-SPEC-0017 Material Specification, 954-6 pre-impregnated tape

WFIRST-IC-SPEC-0067 Process requirement for adhesive bonding

WFIRST-IC-SPEC-0068 Process Specification for Composite Laminate Fabrication

WFIRST-IC-SPEC-0035 Requirements for Machining, Drilling and Trimming of composite structures

WFIRST-IC-SPEC-0032 Non-Destructive Examination Specification and

Defect Acceptance Criteria for Non-Metallics

WFIRST-IC-SPEC-0062 Process Requirements for application of BR 127 primer

WFIRST–IC-SPEC-0069 Process requirement for composite thermal conditioning

2242498 Raw Diamond Tube Stock

2242499 Raw Square Tube Stock

2250600 Raw Gusset panel Stock

2250602 Development Test Specimen, Plug Joint assembly

2250603 Development Test Specimen, T joint assembly

2250604 Development Test Specimen, 3D composite test article

Provided at award Double Lap Shear Test Coupon

2250500 Flight structure assembly

2250578 Large Titanium Node

1.4.2 Reference Documents

The following documents are referenced herein and amplify or clarify the information presented in this document. These documents are not binding regarding the requirements of this document.

Document Number Title

NPR 7123.1 NASA Systems Engineering Processes and Requirements

GPR 8700.6 Engineering Peer Reviews

ASTM D 1002 Strength Properties of Adhesives in Shear by Tension Loading

(Metal to Metal)

ASTM D 2344 Short Beam Shear Strength of Oriented Fiber-Resin Composites

ASTM D 2734 Void Content of Fiber-Resin Composites

ASTM-C-297

Standard Test Method for Flatwise Tensile Strength of Sandwich

Constructions

ASTM D 3171 Fiber Content of Resin-Matrix Composites by Matrix Digestion

ASTM E 8 Standard Test Methods for Tension Testing of Metallic Materials

ASTM E 289 Standard Test Method for Linear Thermal Expansion of Rigid Solids with Interferometry

ASTM E 595 Standard Test Method for Total Mass Loss and Collected Volatile

Condensable Material from Outgassing in a Vacuum Environment

ASTM E 1640 Standard Test Method for Assignment of Glass Transition

Temperature by Dynamic Mechanical Analysis

ASTM F 303 Standard Practices for Sampling Aerospace Fluids from

Components

ASTM F 311 Standard Practice for Processing Aerospace Liquid Samples for

Particulate Contamination Analysis Using Membrane Filters

IEST-STD-CC1246D

Product Cleanliness Levels and Contamination Control Program

1.5 Order of Precedence

In the event of a conflict between documents, the WFIRST-IC-SOW-0001 sets the order of precedence.

2 REQUIREMENTS

2.1 Material Process Requirements

2.1.1 Process Control

2.1.1.1 Workmanship

Workmanship shall be consistent with producing high-quality flight hardware. The vendor shall follow

WFIRST Specifications listed in this specification. The Contractor shall also provide internal workmanship specifications, workmanship standards, standard operating procedures, and non-destructive examination procedures for review and approval by GSFC. Personnel that work on the IC

Flight Unit or related hardware shall be trained and qualified per an in-house training program, approved by GSFC. Personnel trained on the processes shall be maintained throughout the program for assurance of process control.

Samples shall be removed from stocks for the purposes of characterizing the material. The tables below state the minimum acceptable sampling requirements. The sampling requirements apply to samples with valid test results. Sufficient spare coupons shall be fabricated to ensure that the required number of valid test results is obtained.

The test configurations shall be reviewed and approved by WFIRST prior to testing.

2.1.2 Material Requirements

2.1.2.1 Pre-impregnated (prepreg) graphite cyanate-ester material

The prepreg manufacturer shall meet the required prepreg material properties of Hexcel’s M55J/954-6 and T300/954-6 unidirectional tape as specified in WFIRST-IC-SPEC-0017.

2.1.2.1.1 Material lot Acceptance Test

2.1.2.1.1.1 Tube Laminate

The Contractor is responsible for conducting material lot acceptance testing for each new lot of material received from the prepreg manufacturer. The Contractor shall fabricate panels with the tube lay-up and complete room temperature and cold testing identified in Table 1. The composite panels shall be fabricated per WFIRST-IC-SPEC-0068 and meet all requirements therein before fabrication of flight component parts. GSFC will review and approve the use of this material before any parts are manufactured.

Table 1. Tube Laminate Tests

PROPERTY TEST METHOD QTY NOTES

293K 170K

Glass

Transition

Temperature, Tg

ASTM E 1640 2 1 from each end of corner of a 55 mm x 8 mm panel

GSFC will perform the Tg tests

Fiber

Volume

Fraction, Void Volume

Fraction

ASTM D 3171

ASTM D 2734

FXZ

SU

Short Beam

Shear

ASTM D 2344 8

FZZ

TU

Flatwise

Tension

Drawing

2070321

ASTM C 297

12 12 αXX ASTM E 289 2 Size: 2” (hoop)x6” (axial)

Taken from panel with a minimum of 2 inches from the edge

GSFC will perform the tests

2.1.2.1.1.2 Gusset Laminate

The Contractor shall fabricate gusset laminate samples per WFIRST-IC-SPEC-0068 and drawing

2250600 sufficient to perform the following tests:

Table 2. Gusset Laminate Tests

PROPERTY TEST METHOD QTY LAMINATE

293K 170K Drawing 2070321

ASTM-C-297

12 12

2250600 αXX ASTM E 289 2* 2250600

Short Beam Shear ASTM D 2344 5 TBD

Glass Transition Temperature, Tg ASTM E 1640 2 2250600

Fiber Volume Fraction, Void Volume Fraction ASTM D 3171

3 2250600

*The Contractor shall only fabricate the thermal strain specimens. The testing will be conducted at GSFC.

2.2 Outgassing

The Contractor shall deliver hardware containing only materials that have a total mass loss (TML) less than 1.00% (after subtracting water vapor regain (WVR)) and a collected volatile condensable mass

(CVCM) less than 0.10% as determined in accordance with ASTM E 595. If a material exceeds these maximum limits, the Contractor shall be required to either, replace with a compliant material, bring it into compliance via a proper bake-out, or submit a Materials Usage Agreement (MUA) for its usage. In general, a material is qualified on a product-by-product basis as referenced in the GSFC database:

http://outgassing.nasa.gov/.

2.3 Concurrent Process development

Several specifications will be developed during the course of this work. The Contractor shall provide inputs to the development of IC specific processes and their subsequent specifications. This would include revisions to the currently existing WFIRST process specifications.

http://outgassing.nasa.gov/ http://outgassing.nasa.gov/

Per the SOW, the following specifications are expected to be developed. However, the list of specifications is not limited to the ones shown. The processes in these specifications will be called out in IC test assembly and flight hardware drawings.

Figure 1. Flight Structure Fabrication Specification Flow-down

2.4 Process Control Requirements

2.4.1 Cured laminate

Process control testing requirements are identified on engineering drawings and WFIRST- IC SPEC-

0068.

2.4.2 Primed Parts

Process control requirements for each lot of primed parts including post process inspections and lap shear testing are defined in WFIRST-IC-SPEC-0062.

2.4.3 Adhesive

Process control requirements for adhesive bonding, including hardness and lap shear testing, are defined in WFIRST-IC-SPEC-0067.

2.4.4 Non Destructive Examination (NDE)

Process control requirements for NDE are defined in WFIRST-IC-SPEC-0032.

2.4.5 Machining Process

The Contractor shall machine all composite materials per WFIRST-IC-SPEC-0035. The Contractor shall verify the finishing method by performing 100 % inspection on all development articles and 10% sampling for Flight tubes and gussets after GSFC approves the process.

2.4.6 Thermal conditioning

Composite stocks/parts/assemblies shall be thermal conditioned per engineering drawing and WFIRST-

IC-SPEC-0069.

2.5 Fabrication Process Development Requirements

2.5.1 Square Section Tube Development

The Contractor shall demonstrate the ability to manufacture square section tube stocks, by fabricating three stocks per drawing 2242499 and meeting all drawing requirements before and after thermal conditioning. The Contractor shall manufacture, test, and inspect, using the same techniques anticipated in support of flight hardware. Stocks shall be fabricated sequentially and serialized. The following tests are required of each stock.

Table 3. Square Development Tube Tests

293K 140K

Tg ASTM E 1640 2* Size: 55 mm (hoop dir) x 8 mm

1 from each end of tube

FV/VC ASTM D 3171

ASTM D 2734

8 1 from center of each flat on each end of tube

EXX

T ASTM D 3039 8 1 from center of each flat, one end only

Edgecoat per WFIRST-IC-SPEC-

FXZ

SU ASTM D 2344 8 8 1 from center of each flat on each end of tube

FZZ

TU ASTM C 297 8 8 1 from center of each flat on each end of tube αXX ASTM E 289 1* Size: 2” (hoop)x6” (axial)

* Tests performed by GSFC

The three tube stocks shall be delivered to GSFC after all test specimens are removed. With approval of

GSFC, stocks may be shorter than the drawing requirements to obtain necessary testing samples. The

Contractor shall not proceed with fabrication of any production tubes until GSFC has reviewed the results.

2.5.2 Diamond Section Tubes

The Contractor shall demonstrate the ability to manufacture diamond section tube stocks by fabricating three stocks per drawing 2242498; the stocks shall meet all drawing requirements including thermal conditioning. Using the same techniques anticipated in support of flight hardware, the Contractor shall manufacture, test, and inspect the stocks. Stocks shall be fabricated sequentially and serialized. The following tests are required of each stock.

Table 4. Diamond Tube Tests

293K 140K

Tg ASTM E 1640 2* Size: 55 mm (hoop dir) x 8 mm

1from each end of tube

FV/VC ASTM D 3171

8 1 from center of each flat on each end of tube

EXX

T ASTM D 3039 8 1 from center of each flat, one end only edgecoat per WFIRST-IC-SPEC-

FXZ

SU ASTM D 2344 8 8 1 from center of each flat on each end of tube

FZZ

TU ASTM C 297

ASTM C 297

8 8 1 from center of each flat on each end of tube αXX ASTM E 289 1* Size: 2” (hoop)x6” (axial)

* Tests performed by GSFC

The three tube stocks shall be delivered to GSFC after all test specimens are removed. With approval of

GSFC, stocks may be shorter than the drawing requirements to obtain necessary testing samples. The

Contractor shall not proceed with fabrication of any production tubes until GSFC has reviewed the results and a flight MRR has been held.

2.5.3 Double Lap Shear Test Articles

The Contractor shall develop processes for fabricating and testing double strap assemblies per drawing

(details will be developed after award of contract) by fabricating a minimum of 10 assembly variations consisting of 5 parts each. 50% of these will be tested at room temperature and the remainder will be tested at 170K. All components shall be bonded per WFIRST-IC-SPEC-0067. The Contractor shall thermal cycle all double strap assemblies per WFIRST–IC-SPEC-0069 and shall provide NDE per

WFIRST-IC-SPEC-0032 before and after thermal cycling. The Contractor shall place instrumentation for double lap shear testing per Figure 2 (Note 5.2.1 is for an example and may not be the same bond configuration). The exact test configuration shall be reviewed and approved by WFIRST. The

Contractor shall also provide any additional information that is necessary to understand the failure modes of these assemblies.

Figure 2. Double Lap Shear example

Figure shown as an example of Double lap shear. These may be titanium, composite and the bond area may be circular

2.5.4 Adhesive Control

The Contractor shall, as a part of concurrent engineering, develop processes for injecting adhesive in a controlled fashion. The Contractor shall demonstrate techniques for injection, bond shape control, and bond-line control for bonded assemblies with limited access for clean up or inspection. These demonstrations shall include tapered bonds, blind injections, injecting adhesive vertically similar to the

Fight assembly, and evaluating other issues encountered in the Flight assembly. The Contractor shall provide recommendations for injection hole locations, and adhesive setback for test articles. The

Contractor shall present adhesive control examples for test configurations such as the 2250602 and the

2250603 at each of the higher level test reviews call out in the Statement of Work WFIRST-IC-SOW-

0001.

2.5.5 Spot bonding Process for Adhesive Control

2.5.5.1 Lap Shears Spot bonding Test

The Contractor shall fabricate and test two sets of single-lap shear specimens to demonstrate the circular injection process for adhesive control on GSFC test assemblies. The bond diameters will be generated by GSFC. Each set will include 10 lap shears (2 sets of 5-finger bonded assemblies).

a. The first set will consist of a single injection bond. The Contractor shall documenting the time and pressure required for a single injection hole.

0.125”

1.00”

0.375”

0.375” Strain gages on top and bottom of both outer adherends (4 total)

EXTENSOMETER

Ambient Tests Only

1.25”

Centered across width

0.50” min to grips Strain gage on top side only

Strain gage on top side only

b. The second shall be a single injection bond with a taper and proceed with the same process identified in section 3.5.5.1.a.

Each set of two will have one set tested at room temperature and one set tested at 170K. The Contractor shall provide test result for the room temperature before bonding the cold test article.

2.5.6 Plexi-glass Trials for Spot Bonds

The Contractor shall provide testing to insure the spot bonds are controlled. This shall be done with

Plexiglas trials.

a. One set of trials will be done with shims and a controlled bond-line with no taper.

b. The next trial will set the bond area at extreme end of the tolerance (minimum and maximum) to create the worst case taper. The Contractor shall demonstrate that the spot can still be controlled.

2.5.7 Process for Adhesive Shape Control

The Contractor shall fabricate and test two sets of single-lap shear specimens to demonstrate the damming process for adhesive control on GSFC test assemblies. Each set will include 10 lap shear specimens (2 sets of 5-finger bonded assemblies).

c. The first set will consist of a single injection bond. The Contractor shall documenting the time and the pressure required for the single injection hole, with no dams (control samples).

d. The second shall be us a single injection bond with TEFLON-tape set back ¼ inch off the both ends of the lap-shears.

Each set of two will have one set tested at room temperature and one set tested at 170K. The Contractor shall provide test result for the room temperature before bonding the higher order test article.

2.5.8 Additional process verification for Adhesive lot differences

The Contractor shall fabricate and test single lap shear specimens to verify injection pressure required for each new lot of structural bonding adhesive. The Contractor shall perform slump tests, pressure tests, pot life test on all lot of material. The contract shall document and report all the findings. GSFC will modify WFIRST-IC-SPEC-0067 to incorporate all changes required for flight fabrication.

2.5.9 Process verifications for variation in adhesive mixes

The Contractor shall provide processing verifications to insure that variances in the mixing and the time for adhesive pot-life are well defined for Flight application. The Contractor shall fabricate plates for

Vibrating plates, CTE, hardness, and outgassing to establish the adhesive baseline using the mix ratio and post cure used on flight.

2.5.10 Clip injection process

The Contractor shall fabricate and develop an injection process for all configurations of titanium clips on the flight structure. This would also include any tacking methods that will insure bond line geometry is in compliance with drawing requirements. GSFC/WFIRST will approve method used for flight application.

2.5.10.1 Click Bond Fastener Component and Bond Strength Test

The Contractor shall bond and test Click bonds components per drawings and documents using the same techniques used on the flight assemblies. These will be provided after award of contract.

2.5.11 Repair Tubes and Remove Clips or Bonded Joints

The Contractor shall provide a procedure for repair of tubes, removal of clips if bond line thickness is out of tolerance, and a plan for removing tubes or gussets if there is a problem. The Contractor shall present a written plan that will be reviewed and approved but WFIRST.

2.6 Development Test Assemblies

2.6.1 Higher Order Joints (Plug Joint, Double T, and Diagonal)

2.6.2 Subscale Test Articles

The Contractor shall fabricate 10 samples each of the following: Plug Joint 2250602, T-Joint test article

2250603, and 3D joint test assembly per drawings 2250604.

2.6.3 Subscale Testing of Subscale Test Articles

The contract shall test all test assemblies 2250602, 2250603, and 2250604. They will be provided after award of contract. This plan will include 10 of each of the three assemblies. Of the 10 the contractor shall test 5 assemblies at room temperature and 5 assemblies at 170K.

2.6.4 Additional Plug test articles

The Contractor shall fabricate 18 additional Plug joint assemblies which will be held for future testing.

2.6.5 Clip testing

The Contractor shall fabricate and test 10 clip articles per drawing provided after award of contract and all IC specifications.

2.6.6 Electrical Ground Test Articles

The Contractor shall fabricate test articles per Clip Grounding Test Assembly drawing. These drawing and test plans will be provided after award of contract. GSFC will test articles. The Contractor will develop the process that will meet requirements for the conductivity required for the WFIRST IC assembly.

2.7 INSPECTION and VERIFICATION REQUIREMENTS

2.7.1 Responsibility

The Contractor is responsible for all inspections and tests. Mandatory inspections points shall be determined jointly between GSFC and the Contractor, with GSFC approving all selections.

2.7.2 Material Traceability

The vendor shall provide documentation to prove all deliverables are traceable back to individual lots of raw materials. All marking of the flight structure or marking to aid assembly or in-process operations shall be approved in advance by GSFC. Of particular concern is the possibility of contamination by the marking media.

2.7.3 Non-Destructive Examination (NDE) Requirements and Defect Acceptance

The Contractor shall comply with the GSFC specification WFIRST-IC-SPEC-0032 for NDE and defect acceptance. NDE techniques to be used must be approved by GSFC and shall be demonstrated using defect standards representing all of the subject test configurations. The designs and fabrication of the defect standards shall be the responsibility of the Contractor. The Contractor shall install defects in known locations without identifying them to the NDE inspector.

The Contractor shall perform 100% non-destructive examination at the following inspection points

a. At all composite piece parts at the detail part level after all machining operations are complete.

b. NDE of all joint bond lines per WFIRST-IC-SPEC-0032. A hard copy map of the scanned parts shall be provided with enough resolution to discern size and position of any defects not meeting the defect acceptance criteria.

c. The Contractor shall provide the electronic information based on an agreed format to GSFC at shipping. The Contractor will also provide NDE inspection of the entire structure 2 more times post-delivery: once at arrival to GSFC and once after thermal cycling at GSFC. The format that is agreed to with the Contractor shall be the same format in all inspections.

2.7.4 Assembly Weight

The contactor shall weigh each completed part of the flight structure prior to it being bonded or assembled. To the extent possible, the weight shall be clearly identified by location in the assembly.

This shall be documented as an “as built” weight.

2.7.5 Individual Test Assemblies Inspections

The Contractor shall provide detailed inspection reports on each piece part for all test assemblies including the overall test assembly configuration, full dimensional, NDE and any processes performed on the assemblies.

2.7.6 IC Structure

The Contractor shall perform a dimensional verification of the flight structure relative to the requirements of top assembly drawing 2250500 (TBR). The Contractor shall also meet all dimensional requirements and tolerances defined on the top assembly drawing. The Contractor shall map all the dimensional inspections and provide the data in an electronic format that has been agreed by WFIRST.

2.7.7 Contamination

The Contractor shall verify that contamination requirements per WFIRST-SYS-PLAN-0051 are met prior to shipping.

2.8 Quality Provisions and Test Methods Matrix

The Contractor shall provide quality assurance provisions for all tasks outlined in the SOW and this specification. Table 5 lists the required specifications and test methods used.

Table 5. Quality Assurance Provisions

Process Controls cured laminate fiber volume/void content

(FV/VC)

glass transition temp (Tg)

CTE

EXX

T (tension modulus)

FXZ

SU (SBS)

primed parts primer thickness primer adhesion single lap shear adhesives single lap shear hardness

Per drawing and

WFIRST-IC-SPEC-0068

WFIRST-IC-SPEC-0062

WFIRST-IC-SPEC-0067

ASTM D 3171/2734

ASTM E 1640

ASTM E 289

ASTM D 3039

ASTM D 2344

dimensional

ASTM D 3359

ASTM 1002

ASTM 1002

Shore D

Development Tubes glass transition temp (Tg) fiber volume/void content (FV/VC)

EXX

T (tension modulus)

FXZ

SU (SBS)

FZZ

TU (FWT)

αXX, (thermal strain/CTE)

ASTM E 1640

ASTM D 3171/2734

ASTM D 3039

ASTM D 2344

ASTM C 297

ASTM E 289

NDE WFIRST-IC-SPEC-0032

DESCRIPTION SPECIFICATION TEST METHOD

Pre-preg Misc

Material Lot Acceptance Testing

FXZ

SU (SBS)

FZZ

TU (FWT)

αXX, YY (thermal strain/CTE)

ASTM D 2344

ASTM C 297

ASTM E 289

Outgassing ASTM E 595

Test Assemblies

Double T

Plug Joint

3 D composite joint

Per dwg

Dimensional

IC Structure NDE/dimensional/alignment

2.9 Packaging and Transportation

2.10 Cleanliness

Prior to shipping, all exterior surfaces shall be verified to meet level 300A per IEST-STD-CC1246D using a solvent wash collected per ASTM F 303 and analyzed per ASTM F 311 for particles and ASTM

1234 for non- volatile residue or procedures determined to be equivalent by GSFC. After shipment and upon delivery to GSFC, all exterior surfaces shall be re-examined per the visibly clean, level highly sensitive plus UV, per SN-C-0005.verified as meeting level 300A per IEST-STD-CC1246D.

2.11 Packaging

Packaging and transportation requirements for the IC project deliverables will vary. The categories are as follows:

Development Test Assemblies

IC Flight structure

Spares

2.11.1 Development Test Assemblies

The Contractor shall ship the development test assemblies packaged in wooden boxes providing adequate protection for the assemblies in shipping. The test assemblies shall be double bagged prior to placement in the boxes.

The Contractor shall ship the tested development test assemblies to GSFC upon request. Care will be taken to protect any broken surfaces and to maintain the integrity of the assembly.

2.11.2 IC Flight Structure

The Contractor shall provide a shipping container that will be used for the Flight Structure. This container shall meet all requirements identified in GSFC shipping Spec 540-PG-8700.2.1C, NASA NPR

6000.1H, and NASA-STD-5005D. The design of the container and all materials used in the shipping container shall be approved by GSFC before fabrication begins. The shipping container for the Flight structures shall, as a minimum, meet all contamination requirements listed in this specification as well as the following criteria:

Materials that outgas molecular contamination shall not be used.

Materials generating particulate contamination shall not be used. Areas of concern are, plastic or metal-laminated or coated plastic films that shed particles when abraded and especially at contact points, aluminum surfaces with oxide build-ups, corroded surfaces, improperly designed mechanical joints in fixtures permitting relative movement of parts and abrasion at the contact points and improperly applied paints.

Surface cleanliness of materials in contact with flight hardware shall be equal to the required cleanliness level of flight hardware being contacted.

Wood, silicones, foams, and polyvinyl chlorides (PVCs) shall be prohibited as they pose serious molecular contamination threats.

Metals shall be finished so as to not generate particles.

Packaging shall meet ESD requirements per ANSI/ESD S20.20.

The Flight structures shall be double bagged prior to placement in the container. GSFC quality will be present while packaging the structures prior to shipping to insure all requirements are met.

2.11.3 Spares

All spare tubes, gussets, and fittings shall be shipped to GSFC in approved containers. These items shall be packaged in wooden boxes capable of protecting the items in shipping. The items shall be packaged with desiccant.

Appendix A Abbreviations and Acronyms

Abbreviation/

Acronym

DEFINITION

TBD To Be Determined

TBR To Be Revised

TBS To Be Scheduled

NDE Non-Destructive Inspection

WFIRST Wide Field Infrared Survey Telescope

TBA To be assessed

GSFC Goddard Space Flight Center