NNA17615585Q_SOW_NDE_Evaluation_XRAY_CT.pdf

NNA17615585Q

Latest Revision Version can be validated at http://minx.arc.nasa.gov

Statement of Work

Heatshield for Extreme Entry Environment Technology (HEEET)

Non-destructive Evaluation of Large Heatshield

Units Using X-ray Computed Tomography

HEEET Document-4035

02.17.2017

Ames Research Center Moffett Field, California

National Aeronautics and Space Administration http://minx.arc.nasa.gov/

Table of Contents

1.1 BACKGROUND

1.2 CT SCAN REQUIREMENTS

1.3 DATA REDUCTION AND INSPECTION SERVICES

1.3.1 basic delivery of reconstructed volumes

1.3.2 option A: Stitching of individual scans Generation of custom cutting surfaces

1.3.3 option B: defect detection inspection services

2 APPLICABLE DOCUMENTS:

2.1 GOVERNMENT DOCUMENTS

3 SOW REQUIREMENTS/PROCESS SPECIFICATION

3.1 ROLES AND RESPONSIBILITIES

3.2 US CORPORATION OR ITAR CERTIFIED BUSINESS

3.3 SOW REVISIONS

3.4 ENGINEERING DOCUMENTATION

3.4.1 NASA provided Engineering Drawings/Models

3.4.2 Vendor Delivered Engineering Drawings/Models

3.5 DELIVERIES

4 MANAGEMENT AND REPORTING

4.1 ON-SITE GOVERNMENT REPRESENTATIVE

4.2 NOTIFICATION

4.3 REVIEWS AND MEETINGS

4.3.1 Technical Interchange Meetings (TIM)

4.3.2 GSE Design Review

4.3.3 Test Readiness Review (TRR)

4.3.4 Pre-Ship Review (PSR)

4.4 SUBCONTRACTOR CONTROL

4.5 SCHEDULE MANAGEMENT

4.6 END ITEM DATA PACKAGE (EIDP)

5 CONTRACTOR TASKS/WORK PHASES

5.1 PRE-PHASE 1: SCAN CAPABILITY DEMONSTRATION

5.2 PHASE 1: TOOLING AND PROCESS DEVELOPMENT

5.3 PHASE 2: ETU INSPECTIONS

5.3.1 Task 2.1 – ETU Inspection After Assembly

5.3.2 Option A - Inspection of ETU with any repairs

5.3.3 Option B – ETU Inspection After Environmental Testing

5.4 PHASE 3: ADDITIONAL ETU INSPECTIONS

5.4.1 Option C – ETU Inspection After Phase 2

5.5 GOVERNMENT FURNISHED EQUIPMENT (GFE)

5.6 TOOLING HARDWARE DELIVERABLES

6 QUALITY ASSURANCE

7 CONTAMINATION CONTROL REQUIREMENTS

8 DELIVERABLES

APPENDIX A: LIST OF REFERENCED DOCUMENTS

APPENDIX B: LIST OF GOVERNMENT FURNISHED EQUIPMENT (GFE)

SCOPE

The Heatshield for Extreme Environments Technology (HEEET) project is planning to build a large (1-m diameter) heatshield unit for manufacturing demonstration and testing. This unit must be screened using X-ray Computed Tomography (CT) to identify and characterize any flaws present within the assembly. This Statement of Work (SOW) defines the extent of this anticipated Non-Destructive Evaluation (NDE) effort.

While the structures will not see spaceflight use, the procedures and processes shall conform to typical spaceflight processing and inspection requirements, except as noted. This document shall describe the scope, background, applicable documents, requirements, and associated program management needed to complete the tasks required by the Government.

1.1 BACKGROUND

The HEEET Project, collaboratively funded by NASA’s Space Technology Mission Directorate under the Game Changing Development Program (GCDP) and NASA’s Science Mission Directorate (SMD), seeks to mature a game changing Woven Thermal Protection System (WTPS) technology to enable in-situ robotic science missions recommended by the NASA Research Council (NRC) Planetary Science Decadal Survey (PSDS) committee. A primary deliverable for the HEEET Project is an Engineering Test Unit (ETU). A flight-like WTPS heat shield will be assembled on a flight-like carrier structure and put through a series of environmental tests. There are four primary goals associated with the development, manufacturing, and testing of the ETU:

1. Verification of structural performance of ETU and structural model correlation

2. Demonstration of manufacturability at a 1-meter scale

3. Demonstration of inspection and defect identification of entire heat shield at 1-meter scale

4. Demonstration of NASA’s ability to transfer prototype component manufacturing and inspection processes to outside partners, levy efficient and effective requirements, and verify that delivered hardware is acceptable

To accomplish these goals, the Project is building a 1-meter Engineering Test Unit (ETU). The ETU will consist of a tiled woven TPS system (HEEET) assembled on a representative composite carrier structure.

The HEEET woven TPS architecture consists of a high-density all carbon surface layer (designed to manage recession) below which is a lower density layer composed of a blended carbon-phenolic yarn (insulating layer to manage heat load). A layer-to-layer weave is utilized in HEEET, which mechanically interlocks the different layers together. This woven architecture, Figure 1, is then infused with phenolic resin.

This dual-layer approach promotes mass efficiency by limiting the thickness of the high-density outer layer. By customizing the thicknesses of the different layers, the mass can be optimized for a given mission.

However, due to manufacturing limitations in the weaving of the HEEET preform, heatshields will be constructed as an assembly of panels. Following the weaving of the preform, each panel is rough cut from the dry woven fabric to the proper dimensions, formed into the required curvature, infused with a phenolic resin, machined to a final size and shape, and then bonded onto the carbon composite substructure. Between the acreage tiles and the composite substructure is a bondline of HT-424 epoxy film adhesive that is approximately 625 m thick. This bond is critical to ensuring the tiles do not detach from the carrier structure beneath as the system experiences the various environmental loads to which it is exposed during a mission.

Figure 1. Illustration of HEEET material 3-D weaving process and a cross section of infused material showing the dual layer.

The tiled assembly requires that the woven TPS panels be joined together. The selected seam concept, shown in Figure 2, employs a gap filler that consists of a narrow segment of HEEET weave that is cut from the weave, formed and infused in the same manner as the acreage material, and then compressed in the in-plane direction. The compression breaks down the phenolic network, resulting in a more compliant material than the acreage. This softened material is called Expanding Softened HEEET (ESH). The ESH seam material maintains the same composition of the acreage material and has the same TTT orientation with the higher density, all carbon layer at the top. However, the compression process does induce slight density reduction in local regions of the ESH material.

Figure 2. Illustration of ESH in between sections of acreage HEEET material.

After the acreage tiles have been bonded to the structure, gaps approximately 1” wide are routed in-between the tiles. The ESH gap filler is then inserted into these routed channels and is bonded with a nitrile phenolic film adhesive. The adhesive bondline thickness on the sides and base of the channel will be approximately 200 m and 500 m, respectively. The adhesive in this joint transfers structural loads between tiles and the gap filler and must be thin enough to avoid excessive gap opening due to accelerated recession from the aerodynamic heating during atmospheric entry.

Infused High Density Carbon Weave

Infused Lower Density Blended Yarn

Weaving Operation

The ETU will be designed and constructed to satisfy the demanding flight environments of a Saturn probe of this size. Although the ETU will not see space flight use, it will be tested with the anticipated spaceflight loads and therefore needs to be fabricated and inspected with methods conforming to typical spaceflight processing and inspection requirements.

The ETU is a spherically-blunted cone with a half-cone angle of 45 degrees, base diameter of 1 m, height of 0.46 m, and shoulder radius of 0.146 m. The complete aeroshell assembly includes one nose cap, 6 inner tiles and 12 outer tiles and 30 gap filler segments. The maximum dimension of any acreage tile is

0.235 m x 0.445 m and the longest running length of any gap filler is 0.475 m. All TPS segments will be bonded to the underlying structure using HT-424 adhesive which will cover a surface area of 1.03 m2. The fully assembled aeroshell will have an approximate mass of 65 kg. This is the mass of the part that needs to be scanned. However, the mass of the part that will be shipped, with the associated shipping crate and ground support equipment (GSE) will have a mass of approximately 365 kg. Figure 3 shows the layout of ETU TPS panels and seams as well as a cross section of the ETU in its shipping configuration. All required vendor facilities (scanner, manipulator stage, scanning chamber, doors in the facility, etc.) shall be capable of accommodating the mass and size of the ETU.

The manipulation of the ETU will require custom ground support equipment (GSE). The vendor can opt to design and fabricate this GSE directly or NASA can collaborate with the vendor in the design and then provide the GSE as Government Furnished Equipment (GFE).

The carrier structure includes a 0.635 cm thick stainless steel metallic ring structure that is attached to the laminate skin using 60 fasteners. Figure 4 shows the carrier structure without TPS panels. Please note that the metallic ring cannot be detached during scanning. Figure 5 illustrates the approximate material

1m

Figure 3: Layout of ETU TPS panels and seams (left) and cross-section of ETU mounted within the shipping container on the support structure (right) thicknesses and densities that must be penetrated to obtain a scan through the vehicle in areas that include the stainless steel ring.

Figure 4. ETU carrier structure showing the metallic ring inside

Figure 5: Material stack with approximate thickness and density of each material

Prior to the CT scanning of the ETU aeroshell, NASA will provide the vendor with a spare ETU carrier structure without the tiles or gap fillers yet installed for application studies. This part is representative of the final size and shape of the ETU aeroshell. The vendor will use this part to develop methods for holding, maneuvering and scanning the final aeroshell, with a particular focus on methods to minimize the impact of the metallic ring.

1.2 CT SCAN REQUIREMENTS

In proving that the ETU was built without unacceptable defects and that the ETU survived the environmental tests without developing detrimental flaws, it is imperative to perform Non-Destructive Evaluation (NDE) of the entire vehicle. The HEEET project has previously assessed multiple NDE techniques and has baselined the use of CT for screening the adhesive bondlines in the seams surrounding the gap fillers and at the base bond between the tiles and the carrier structure. Since the units cannot be dismantled after assembly, in order to scan these regions, a CT machine/apparatus that can house the ETU will be needed. The units do not have to be scanned in a single operation. A series of scans covering the regions of interest is acceptable.

The ETU will undergo inspection following the completion of assembly and again following the environmental test series. It is possible that NASA will request an additional scan prior to testing if the first scan reveals flaws that need to be repaired. The repairs are likely to be small (approximately 5 cm x 5 cm) and localized, so it is possible that only local scans will be required. If methods exist to achieve higher resolution for inspection of local repairs, provide details on how this would be accomplished.

The ETU build is tentatively scheduled to be finished in July 2017. Testing is tentatively scheduled to be finished in February 2018. Therefore, the schedule only allows 1 month for outbound shipping of the vehicle, setup by the vendor, CT scanning of the entire vehicle, and return shipping. This tight schedule will require close coordination between NASA and the vendor as well as a well understood and rehearsed plan by the vendor to carry out the work.

The required resolution of the scans is <200 m. This resolution is required to enable the inspection of adhesive joints on the sides of the gap filler that will be < 200 m wide. Higher resolution has significant benefit and proposals that can achieve resolutions of 100-150 m will have a competitive advantage.

Full coverage of the vehicle at this scale may require many scans. The vendor will be required to track the location of each scan of the vehicle and include reference features in the scans to identify the location of the vehicle that is included in the scan.

1.3 DATA REDUCTION AND INSPECTION SERVICES

For each scanning task described in this SOW, the vendor will be responsible for providing the data to NASA for analysis. The following options describe various levels of service that the vendor may propose.

In assessing the various tasks in Section 5, provide cost and schedule associated for each of these different data reduction and analysis options.

1.3.1 BASIC DELIVERY OF RECONSTRUCTED VOLUMES

The vendor is required to provide basic reconstruction services for all scans conducted as part of this SOW.

This entails the post processing of the raw CT data and delivery of the data to NASA in a format that is compatible with Volume Graphics software. Providing the data in any other software format must first be approved by NASA.

1.3.2 OPTION 1: STITCHING OF INDIVIDUAL SCANS GENERATION OF CUSTOM

CUTTING SURFACES

In addition to providing the basic reconstructed scans, this option has the vendor stitch the scans together, trim data that is not of interest, and generate custom cutting surfaces for NASA to conduct the analysis.

Though the entire vehicle will be scanned, the bulk tile material is accepted prior to installation and therefore the majority of the volume scanned is not of interest. The features of interest are the gap fillers and the bondline between the carrier structure and all of the tiles above.

Providing data that can be analyzed and interpreted with ease is critical. To this end, the vendor will examine the feasibility of stitching the various scans together into one cohesive scan. If the size of a fully stitched scan will be prohibitively large, the vendor will provide stitched full vehicle scans that have been trimmed in two different ways. One full vehicle scan will remove the data from the majority of the acreage tiles and the entire composite carrier structure and stainless steel ring, leaving only the gap fillers and the surrounding material (approximately 5mm) in each direction (see Figure 6). Cut planes that are perpendicular to each gap filler in both the radial (red box in Figure 6) and circumferential (blue box in Figure 6) will enable inspection of the entire running length of each gap filler in one comprehensive scan.

Figure 6: Scan with gap fillers only

The other stitched scan will remove everything except the base adhesive bondline and 2mm of material in either direction, moving into the TPS tiles above and the composite carrier below. This scan shall include a cutting surface that is the same nominal geometry as this bondline (NASA will provide CAD of this surface) so the entire bondline can be stepped through at once (see Figure 7). This scan will enable the comprehensive inspection of the entire base adhesive bond. The vendor can propose other techniques to inspect the entire base adhesive layer simultaneously, such as “unrolling” the surface into a single flat plane.

Carrier Structure

Epoxy adhesive

Acreage HEEET Tiles

ESH Gap Filler

Nitrile Phenolic Adhesive

Figure 7: Scan with base adhesive only

1.3.3 OPTION 2: DEFECT DETECTION INSPECTION SERVICES

In addition to providing the basic reconstructed scans, this option has the vendor conduct defect detection inspection services on each of the scans. Definition of defect sizes in each of the areas of interest will be provided by NASA to the vendor. Please describe the defect detection capabilities and services that could be employed to automatically or semi-automatically identify voids and defects in the adhesive layers.

2 APPLICABLE DOCUMENTS:

2.1 GOVERNMENT DOCUMENTS

The government will provide the following documents upon request.

DOCUMENT NUMBER TITLE Use

HEEET -6013-001 ETU Assembly – CAD/Step File Required

HEEET -8002-001 Work Stand Transport Assembly Required

HEEET -8006-001 Shipping Configuration Required

HEEET -8040-001

ETU Coordinate System and MICD – Technical Drawing

Required

HEEET-4011

HEEET Material Handling & Damage Prevention Specification

Required

HEEET-8040 – ETU Coordinate System and MICD will provide the following information to the vendor:

Master Coordinate Frame

Master Locating & Reference Feature

Tile Marking/Numbering System for the Integrated TPS

Bounding Dimensions, internal and External

Mechanical Interface/Bolt Pattern for any ground support equipment

3 SOW REQUIREMENTS/PROCESS SPECIFICATION

This section outlines the SOW requirements for the CT scanning and analysis of the HEEET tiled ETU composite aeroshell.

3.1 ROLES AND RESPONSIBILITIES

The contractor may be referred to as “the supplier”, “the vendor”, or “the contractor” synonymously within this SOW. The NASA Ames Research Center shall act as the customer performing buyoffs at all levels and phases of the contract. The references to NASA, ARC, NASA ARC, NASA Ames Research Center, and the Government shall be used interchangeably within this document. Quality oversight shall be conducted by NASA.

The Vendor shall be responsible for handling/manipulating the test article and any associated GFE while the test article and GFE on the vendors’ premises. NASA shall be responsible for shipping/transporting the test articles and any supporting GFE to and from the vendors’ facility.

3.2 US CORPORATION OR ITAR CERTIFIED BUSINESS

The HEEET material is export controlled. Therefore, it is required that any vendor responding to this RFP is either a US owned corporation or can provide an ITAR certification.

3.3 SOW REVISIONS

In the event that NASA elects to revise the scope of work through the addition of new work tasks, Class I changes to drawings, and/or significant modifications to process specifications herein, advance notice of said changes will be made to the SOW directly and will be communicated to the contractor by the NASA Contracting Officer. Any scope changes, changes to Section 8 Deliverables or contract Line Items (CLINS) shall be negotiated between the contractor and NASA with a subsequent contract modification issued for the scope change. Any subtasks related to this SOW, unless otherwise specified, shall fall under the same contractual obligations specified herein.

3.4 ENGINEERING DOCUMENTATION

The contractor shall deliver required data files and formats necessary to allow NASA to view and post process on NASA computer systems. The vendor shall provide the data in a format compatible with Volume Graphics software. If the vendor has an alternative data viewer, NASA must approve the use of that software. As described in Section 1, it is advantageous for the vendor to provide stitched scans that focus on local areas of interest over the entire vehicle.

The data files provided shall reference tile numbering defined in HEEET-8040, along with some system Datum axis, to describe the areas of the ETU that are included in each scan. These references shall be physically included in the scans and in the name of each file. The vendor shall provide a relative file map, transposed onto HEEET-8040 that indicates the file names and regions of each scan, allowing NASA to target data quickly.

3.4.1 NASA PROVIDED ENGINEERING DRAWINGS/MODELS

If required during the period of performance and/or proposal phases, electronic versions of drawings and models shall be exchanged in the following formats, listed in order of preference:

Pro Engineer Wildfire 5.0, CREO I or II

STEP 201

IGES

CATIA V5.0

STL

The naming convention for NASA Ames Research Center engineering drawings in the HEEET project is:

HEEET-6XXX-YYY-Rev.ZZZ

Where XXX is the drawing number and YYY is the part number. Revision level ZZZ is either “-” indicating an initial release, or an alphabetic character.

A CD-ROM of the drawing/documents package shall be provided. All engineering drawings shall be rendered in Adobe Portable Document Format (PDF) at minimum “D” size resolution. The vendor may request alternate file formats.

3.4.2 VENDOR DELIVERED ENGINEERING DRAWINGS/MODELS

For any hardware the vendor intends to utilize to: handle, transport, lift, manipulate or support the ETU, the vendor shall provide the following:

o COTS Equipment:

Manufacturing Vendor Supplier Part Number Serial Number Load & Stability Rating o Custom Equipment Designed by the Vendor or a Subcontractor:

Technical Manufacturing Drawings Structural Analysis Report Load Rating, and Load Verification Test Report CAD Models shall be available upon NASA’s request, in either STEP or IGES file type.

3.5 DELIVERIES

NASA will be responsible for coordinating and paying for shipping of all hardware to and from the contractor to other NASA locations. Prior to shipping, however, the vendor shall be responsible for checking and ensuring the 10G shock indicators attached to the carrier support GSE are not tripped during any moving, handling or lifting event, required to manipulate the ETU while at the vendor’s facility.

NASA will provide shipping containers, designated as GFE, to transport the ETU structure. The vendor shall be responsible for unpacking and packing the ETU into the NASA provided shipping containers prior to and after scanning. Installation of the carrier structure into the shipping container is defined in drawing HEEET-8006. Handling requirements are specified in HEEET-4011. If it is possible to transport a mobile scanning capability to the NASA facility where the ETU is being fabricated, provide details of this capability and the associated costs.

The vendor shall be responsible for shipping external hard drives with the data back to NASA Ames Research Center. Data must be sent by overnight mail and this shipment is the responsibility of the vendor.

The vendor shall retain a backup of all data for 90 days after delivery.

4 MANAGEMENT AND REPORTING

The contractor shall establish and maintain management operations that shall include the following areas:

Reviews and Meetings

Subcontractor Control

Schedule and Financial Management

Engineering and Manufacturing Data Management

Management and Accountability for Government Furnished Equipment, Material or Information.

4.1 ON-SITE GOVERNMENT REPRESENTATIVE

NASA reserves the right to have in-plant representation at the contractor’s facility and at all major subcontractor sites when performance/verification testing or other operations are being performed. This Government representation may be provided by NASA, or non-Government personnel designated by

NASA.

During this period, the representative shall be onsite for validation of workmanship process, quality control and to expedite mandatory inspection points.

4.2 NOTIFICATION

The contractor shall notify the NASA/ARC Contracting Officers Representative (COR) at least seven (7) calendar days in advance of all mandatory hardware inspections, test activities, and deliveries at either the contractor’s or a subcontractor’s facility to allow timely participation by the NASA/ARC personnel.

4.3 REVIEWS AND MEETINGS

The required meetings are outlined below. The NASA/ARC COR shall have the authority to remove the requirement for meetings. The elimination of reviews and/or meetings shall be captured by written NASA/ARC COR approval.

Summary Reports shall be submitted for all meetings and reviews and, at a minimum, shall include meeting notice, agenda, attendance, review meeting minutes, action items, action item accomplishment responsibility and agreements. The reports shall be distributed to all meeting attendees within 5 work days after the meeting, review, or TIM. Electronic PDF format sent by email shall be acceptable.

The contractor shall organize and present a Kick-Off meeting to a NASA Review Team at the contractor’s facility, unless otherwise agreed by the contractor and NASA/ARC COR, no later than 10 business days after the contract award. The contractor shall present the baseline process for handling, manipulating and supporting the ETU to complete the full CT scan. The contractor shall identify the baseline requirements and initial concept design of any ground support/handling equipment necessary to support this effort.

The contractor shall provide a comprehensive presentation that lays out the approach and planning for the HEEET work task. The presentation shall cover but need not be limited to the following subjects:

Baseline CT Scanning Setup.

Anticipated CT Scan Resolution

Resolution test setup/planning for CT Scan resolution verification

Data reduction and post processing to meet NASA deliverables for bond line inspection.

Handling equipment to reorient the ETU to complete the full Scan.

Key manufacturing requirements for handling/lifting/ground support equipment (GSE)

A Schedule covering all elements of the HEEET work tasks in Microsoft Project format.

Overview of Quality Assurance Plan used to meet SOW requirements.

4.3.1 TECHNICAL INTERCHANGE MEETINGS (TIM)

For the purposes of design transition and communication the contractor is permitted to plan informal, face-to-face technical interchange meetings at the contractor facilities. The contractor shall support review and coordination of technical issues including, but not limited to testing approach, testing setup, GSE manufacturing, GSE Testing. TIM’s are intended to work out technical details prior to any test readiness review or any design reviews.

NASA/ARC or the contractor may initiate a TIM. The said initiator shall provide notice a minimum of 7 working days prior to the proposed meeting date. The contractor shall budget supporting a minimum of 2 TIMs during the period of performance.

4.3.2 GSE DESIGN REVIEW

For the purposes of reviewing the designs and plans for any and all of the handling equipment / ground support equipment (GSE) that the vendor deems necessary to support the CT scanning of NASA provided hardware. The vendor shall plan a GSE Design Review (that can be a virtual Meeting + Chart Exchange) to review with NASA all handling equipment / ground support equipment that the vendor determines will be needed. At that time the vendor is to have near final designs/drawings, test plans, costing, and any subcontractors identified. Upon completion of the meeting, release of vendor drawing package to NASA will serve as approval for manufacturing release.

4.3.3 TEST READINESS REVIEW (TRR)

No less than 14 days prior to any planned test (Resolution Verification, or ETU Scan testing) the contractor shall hold a test readiness review meeting. This meeting can either be virtual/teleconference or on-site at the vendor’s facility. The TRR is intended to identify all necessary resources: Facility, GSE, Personnel, to support the upcoming test and confirm that everyone and everything is ready.

The contractor shall budget supporting a minimum of 2 TRRs during the period of performance, these would cover the Resolution Verification test, as well as the first ETU Scan. Any TRR’s beyond the first completed ETU CT scan can be informal, over the phone or via email.

4.3.4 PRE-SHIP REVIEW (PSR)

The contractor shall hold a Pre-Ship Review at the contractor's facility at the completion of all CT scans prior to shipment of the aeroshell to any NASA Center (ARC, JSC or LaRC) to certify that hardware has been packaged within the NASA provided shipping containers according to specifications. At the time of the PSR, documents and analysis to support fulfillment of the requirements of this SOW for the hardware and CT data being delivered shall be complete and all actions from previous reviews shall be closed.

4.4 SUBCONTRACTOR CONTROL

The contractor shall designate personnel who will be given full responsibility and authority to manage and administer all phases of the work specified by the contract and ensure that all objectives are accomplished within schedule and cost constraints.

The contractor shall designate and identify by name a single employee who shall serve as the point of contact with the NASA/ARC COR for all technical aspects of the Carrier Structure contract.

In the event the contractor elects to subcontract work tasks, the subcontractor shall conform to the same requirements stated herein to manage all program resources, control schedules, and manage engineering, manufacturing and procurement activities. The subcontractor shall perform all necessary configuration management, Quality Assurance, documentation control, and distribution functions.

4.5 SCHEDULE MANAGEMENT

This schedule shall become a key component of status reporting. The format shall be of a Gantt type using Microsoft® Project.

4.6 END ITEM DATA PACKAGE (EIDP)

The contractor shall provide a data package upon completion of each aeroshell CT scan. This data package shall be “phase based” and the following shall be provided for each phase/scan completed.

All Individual Scan Data Files

Stitched scan files as described in Section 1

Data File Relation Map – File and Scan Data locations on the Inspected Test Article.

Details of CT Scanning Machine

Certification Record/Calibration of CT Scanning Machine

Setup Photos

Complete Handling Procedures

Complete Inspection/Scanning Procedures

Non-Conformance & Incident Reports if Applicable

5 CONTRACTOR TASKS/WORK PHASES

The work tasks shall be structured in the following manner:

Pre-Phase 1 Task: Scan Capability Demonstration o Basic demonstration of achievable CT resolution on GFE materials

Phase 1 Task: Tooling and Process Development o ETU interface structure tooling design and fabrication o Process plan development o Demonstration scans on the ETU carrier structure as a surrogate for the fully assembled aeroshell.

Phase 2 Task: ETU Aeroshell Inspection o Task 2.1 – Complete inspection of aeroshell following assembly o Option A – Localized inspection of aeroshell following any necessary repairs to the ETU o Option B – Complete inspection of aeroshell following environmental testing

Phase 3 Task: Additional Aeroshell Inspections o Option C – Additional inspections of the aeroshell

For all tasks requiring CT data reconstruction, provide costs for each of the options outlined in Section 1.3.

The delivery schedule is specified in Section 8 Deliverables. Delivery is further requested “as available” or “as completed” therefore this Statement Of Work states deliveries as “no later than”. The contractor’s proposal shall take this delivery cycle into account.

5.1 PRE-PHASE 1: SCAN CAPABILITY DEMONSTRATION

Exploratory scanning of GFE materials provided by NASA to establish basic feasibility of scanning approach. NASA will provide a sub scale (~10 cm x 10 cm x 6 cm) test article with appropriate materials and material thicknesses to the vendor (similar to the schematic in Figure 5). The scan technique should be representative of what will be done on the full-scale article.

Pre-Phase 1 Deliverables (Required for Phase 1):

1. Report detailing the various scanning approaches employed to scan the sub-scale test article, the scan resolution achieved for each method, and the anticipated scan resolution achievable on the

ETU.

5.2 PHASE 1: TOOLING AND PROCESS DEVELOPMENT

Develop detailed approach for scanning the ETU, including a description of all tooling and associated ground support equipment required to interface and handle, move, maneuver and CT scan the NASA provided aeroshell.

Vendor Option: Design/develop and fabricate or procure any mounting hardware, fixtures or support equipment as outlined in the Detailed Scanning Approach mentioned above.

If the vendor does not have manufacturing capability, NASA will accept the responsibility for fabricating any necessary ETU mounting fixtures or other Ground Support Equipment with guidance from the vendor (e.g. vendor provided drawings of existing mounting hardware.)

ETU Carrier Structure defined by the following drawings:

HEEET-6013-001 ETU Assembly

Phase 1 Deliverables (Required before proceeding to Phase 2 & Phase 3):

1. Vendor planned Pre Scan Review – Report + Virtual Meeting + Chart Exchange – detailing the approach that will be employed for scanning the complete ETU and for conducting local scans to inspect repairs as well as the data reconstruction techniques that will be applied to the data.

2. Vendor planned Preliminary Design Review (PDR) – Virtual Meeting + Chart Exchange – to review with NASA all tooling and ground support equipment that the vendor determines will be needed for Phase 2 & 3. Vendor to have preliminary designs, costing, and any subcontractors identified if vendor will be fabricating tooling.

3. Vendor planned Critical Design Review (CDR) – Virtual Meeting + Chart Exchange + Release of Vendor Drawing Package – for all hardware to be fabricated by vendor prior to NASA final approval for manufacturing release.

4. Fabrication of all piece parts, tooling and ground support as described at the CDR.

5. Inspection reports on all completed tooling, verification that they will meet ETU interface requirements

6. Scanning of the spare ETU carrier structure (without TPS tiles or adhesive bondlines) to demonstrate tooling and scanning methodologies. The spare ETU carrier structure mounted in the shipping crate on the support structure is shown in Figure 8.

5.3 PHASE 2: ETU INSPECTIONS

5.3.1 TASK 2.1 – ETU INSPECTION AFTER ASSEMBLY

CT scan the complete HEEET ETU and provide electronic data package to NASA. NASA personnel may be on site to view the setup and execution of the first scans. Vendor will review data from the first scan with NASA personnel and wait for authorization to proceed prior to completing further scans.

Task 2.1 Deliverables:

1. First CT scan of ETU and data review with NASA

2. End Item Data Package – Covering CT scan results of the HEEET ETU

5.3.2 OPTION A - INSPECTION OF ETU WITH ANY REPAIRS

CT scan the HEEET ETU in selected areas with repairs and provide electronic data package to NASA. Though the number and location of repairs that will be necessary is unknown, provide cost and schedule for this task assuming that two repair locations must be inspected in the locations show in Figure 9. NASA personnel may be on site to view the setup and execution of the first scans. Vendor will review data from the first scan with NASA personnel and wait for authorization to proceed prior to completing further scans.

Option 2A Deliverables:

1. First CT scan of repaired region and data review with NASA

2. End Item Data Package – Covering CT scan results of the HEEET ETU

Figure 9: Potential ETU Repair Locations

Figure 8: Spare ETU carrier structure

5.3.3 OPTION B – ETU INSPECTION AFTER ENVIRONMENTAL TESTING

CT scan the complete HEEET ETU and provide electronic data package to NASA. NASA personnel may be on site to view the setup and execution of the first scans. Vendor will review data from the first scan with NASA personnel and wait for authorization to proceed prior to completing further scans.

Option 2B Deliverables:

1. Complete CT scan of ETU and data review with NASA

2. End Item Data Package – Covering CT scan results of the HEEET ETU

5.4 PHASE 3: ADDITIONAL ETU INSPECTIONS

5.4.1 OPTION C – ETU INSPECTION AFTER PHASE 2

NASA may choose to conduct an additional inspection for further evaluation following completion of the scans in Phase 2. Vendor to conduct an additional scan of the complete HEEET ETU and provide electronic data package to NASA. NASA personnel may be on site to view the setup and execution of the first scans. Vendor will review data from the first scan with NASA personnel and wait for authorization to proceed prior to completing further scans.

Option 3C Deliverables:

1. Complete CT scan of ETU and data review with NASA

2. End Item Data Package – Covering CT scan results of the HEEET ETU

5.5 GOVERNMENT FURNISHED EQUIPMENT (GFE)

Contractors electing to not use the existing GFE shall itemize the non-recurring and recurring engineering costs in the response to this statement of work. All GFE is listed in Appendix B.

5.6 TOOLING HARDWARE DELIVERABLES

All tooling designed, fabricated and used for the inspection of the HEEET related hardware in this SOW shall be delivered to NASA upon completion of Phase 3. The Vendor shall be responsible for shipping any fabricated GSE to ARC. Final contract invoice payments shall not be approved prior to acceptance of tooling hardware deliverables.

6 QUALITY ASSURANCE

CERTIFICATION AND CALIBRATION OF TEST EQUIPMENT

The contractor shall only perform testing with equipment that has a current calibration and/or certification. A NASA representative will be on site to review initial scans for each of the various contract phases. NASA will authorize continued scanning for each phase after initial review.

7 CONTAMINATION CONTROL REQUIREMENTS

The Contractor shall maintain cleanliness during inspection of all hardware in accordance with NASA Ames Research Center Document Specifications:

o HEEET-4011, HEEET Material Handling & Damage Prevention Specification

8 DELIVERABLES

NASA assumes an award date of March 20, 2017. The contractor shall package the items required under this contract in preparation for shipping. NASA will coordinate and pay for shipping to/from the contractor to one of the following NASA locations:

1. NASA Ames Research Center

2. NASA Johnson Space Center

3. NASA Langley Research Center

Item Milestones/ Deliverables Qty Delivery / Acceptance

Date

PRE-PHASE 1

Report detailing the various scanning approaches employed while scanning the sub-scale test article, the scan resolution achieved for each method, and the anticipated scan resolution achievable on the ETU

1 April 15, 2017

PHASE 1

Detailed ETU Scanning Approach Report including a description of all tooling and associated ground support equipment required to interface and handle, move, maneuver and CT scan the NASA provided aeroshell.

1 May 1, 2017

Optional Task: Contractor Drawing Package for all required Hardware and Support Equipment

If hardware option is not exercised, Vendor to provide the Government with all necessary drawings so that NASA can fabricate required hardware.

May 1, 2017

Or delivery of equipment/interface drawings to Government by April 1, 2017.

Report detailing demonstration scans on the ETU carrier structure as a surrogate for the fully assembled aeroshell

1 June 1, 2017

PHASE 2

Task 2.1 – End item data package and Report detailing full scan of ETU post assembly

Delivery no later than 10 days after receipt of ETU

Option A – End item data package and Report detailing full scan of ETU post repairs

Delivery no later than 10 days after receipt of ETU

Option B – End item data package and Report detailing full scan of ETU post environmental testing

Delivery no later than 10 days after receipt of ETU

PHASE 3

Option C – End item data package and Report detailing additional scan of ETU

Delivery no later than 10 days after receipt of ETU

APPENDIX A: LIST OF REFERENCED DOCUMENTS

All referenced documentation identified in the SOW shall apply in the situations where they are specifically referenced.

DOCUMENT NUMBER TITLE

541-PG-8072.1.2 GSFC Fastener Integrity Requirements

AIA/NAS NAS 999 Nondestructive Inspection of Advanced Composite Structures

APR 7120.8 Program/Project Reviews for Space Flight Systems

ASTM E-2533 Standard Guide for Nondestructive Testing of Polymer Matrix Composites Used in Aerospace Applications

ASTM E-2662 Standard Practice for Radiologic Examination of Flat Panel Composites and Sandwich Core Materials Used in Aerospace Applications

MIL-STD-882 Standard Practice for System Safety

MIL-STD-889 Dissimilar Materials

NASA-STD-8739.7 Electrostatic Discharge Control

NPD 8730.5 NASA Quality Assurance Policy

NPR-8715.3 NASA General Safety Program Requirements

HEEET-4011 HEEET Material Handling & Damage Prevention Specification

APPENDIX B: LIST OF GOVERNMENT FURNISHED

EQUIPMENT (GFE)

Item Name Part Number Quantity

Material Stack-up Test Article TBD 1

HEEET ETU Shipping Container HEEET-6008 1

HEEET ETU Spare Carrier Structure and GSE HEEET-6001-01 (SN: 8135785) 1 http://gdms.gsfc.nasa.gov/